153200083-ZW-Final Databook

FINAL
MANUFACTURING
DATABOOK
PAN AMERICAN ENERGY
CUSTOMER PO: 4100126575
TAG NUMBER: JE‐1101A
PROJECT: 153200083
PUMP TYPE: ZW 14X10X24
FOR 7.2.3‐04 Rev. 0
FINAL MANUFACTURER DATA BOOK
INDEX
SECTION 1
PUMP INSTALATION AND OPERATION MANUAL
SECTION 2
PUMP AND/OR PUMP SYSTEM TECHNICAL INFORMATION
SECTION 3
DRAWINGS & DIAGRAMAS
SECTION 4
MAIN EQUIPMENT TECHNICAL INFORMATION
SECTION 5
AUXILIARY EQUIPMENT TECHNICAL INFORMATION
SECTION 6
QUALITY PLAN & PROCEDURES
SECTION 7
INSPECTION & TEST REPORTS AND OTHER CERTIFICATES
SECTION 1
ZW
Installation, Operation and Maintenance Manual
ZW
Split Case, Centrifugal Pump
FOREWORD
These units are horizontal split case centrifugal between bearings pumps and identified by Ruhrpumpen as
ZW.
It is recommended that the services of a Ruhrpumpen installation technician be employed for the
installation and initial starting of the pump. Such service will help to ensure the user that the equipment is
properly installed, and will provide an excellent opportunity for the plant operator to receive useful tips
and guidelines relative to the unit. The tools and/or equipment referenced in this manual are not supplied
by Ruhrpumpen unless specifically ordered. This pump design can be serviced with standard maintenance
tools.
Instructions in this manual are written for trained, experienced technicians who are familiar with the basic
principles and tools involved in the installation, care and service of a pump and who, as part of their trade
education have acquired the ability to interpret and follow the detailed specifications required for such
installation, care, and service. Successful operation of the unit is dependent on careful study of the manual
and a well-planned maintenance program.
A complete reading of this manual by personnel in contact with the pump is essential to safety. Incorrect
installation, operation or maintenance can result in personal injury or death to personnel and damage to
the pump and plant.
IMPORTANT: For any component/accessory that has not been manufactured by Ruhrpumpen and is part of
the pump’s equipment, a complete reading of said component/accessory manufacturer’s manual must be
carried out for further information on proper maintenance procedures and relevant safety warnings.
Correct and orderly installation/assembly is necessary for trouble-free operation of the unit. Ruhrpumpen
does not assume any liability for damage resulting from inadequate installation/assembly. The chosen
location for installation must offer enough space for maintenance activities. Ruhrpumpen recommends
consulting also API Recommended Practices 686 to ensure proper installation in your facility.
Before performing any service function be certain that the unit is separate from its power source or that
the power source is locked out to prevent any form of energy from entering the equipment.
Contact with hot surfaces of the pump can cause severe burns. Care must be taken where such surfaces are
exposed. Care must also be taken to prevent ignition of flammable fluids or other material.
Information in this manual is believed to be reliable, but it is not guaranteed by Ruhrpumpen as to its
completeness or accuracy.
© 2019 Ruhrpumpen
All Rights Reserved.
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Split Case, Centrifugal Pump
INDEX
1. PRODUCT DESCRIPTION ................................................................................................................................. 6
1.1 INTRODUCTION ......................................................................................................................................... 6
1.2 PUMP CASE, IMPELLER, AND WEAR RINGS .............................................................................................. 7
1.2.1 Pump Case .......................................................................................................................................... 7
1.2.2 Impeller and Wear Rings .................................................................................................................... 7
1.3 BEARING HOUSING ................................................................................................................................... 7
1.4 LUBRICATION ............................................................................................................................................ 7
2. SAFETY ............................................................................................................................................................ 8
2.1 IDENTIFICATION OF SAFETY INSTRUCTIONS IN THE OPERATING MANUAL ............................................. 8
2.2 QUALIFICATION AND TRAINING OF OPERATING PERSONNEL.................................................................. 8
2.3 HAZARDS IN THE EVENT OF NON-COMPLIANCE WITH THE SAFETY INSTRUCTIONS ............................... 9
2.4 COMPLIANCE WITH REGULATIONS PERTAINING TO SAFETY AT WORK ................................................... 9
2.5 SAFETY INSTRUCTIONS RELEVANT FOR OPERATION ................................................................................ 9
2.6 SAFETY INSTRUCTIONS RELEVANT FOR MAINTENANCE, INSPECTION AND ASSEMBLY WORK ............. 10
2.7 UNAUTHORIZED ALTERATIONS AND SPARE PARTS ................................................................................ 10
2.8 UNAUTHORIZED MODES OF OPERATION ............................................................................................... 10
3. TRANSPORT & STORAGE............................................................................................................................... 11
3.1 SHIPPING ARRANGEMENTS .................................................................................................................... 11
3.2 UNLOADING AND CHECKING EQUIPMENT ............................................................................................. 11
3.3 TRANSPORT ............................................................................................................................................. 12
3.4 STORING .................................................................................................................................................. 14
3.5 CONSERVATION ...................................................................................................................................... 16
4. INSTALLATION............................................................................................................................................... 18
4.1 CONCRETE FOUNDATION PREPARATION ............................................................................................... 18
4.2 LEVELING BASEPLATE .............................................................................................................................. 20
4.3 GROUTING*............................................................................................................................................. 21
4.3.1 Equipment/Material Required ......................................................................................................... 22
4.3.2 Grouting Precautions ....................................................................................................................... 22
4.3.3 Grouting Procedure .......................................................................................................................... 22
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Split Case, Centrifugal Pump
4.4 PUMP VERTICALIZATION......................................................................................................................... 24
4.4.1 Vertical Pump Unmounting .............................................................................................................. 24
4.4.2 Vertical Pump Mounting .................................................................................................................. 26
5. PIPING AND ALIGNMENT .............................................................................................................................. 27
5.1 PIPING THE SYSTEM ................................................................................................................................ 28
5.2 HORIZONTAL SHAFT ALIGNMENT ........................................................................................................... 31
5.3 DRIVE SHAFT PUMP ALIGNMENT ........................................................................................................... 40
5.4 VERTICAL SHAFT ALIGNMENT ................................................................................................................. 41
6. LUBRICATION ................................................................................................................................................ 42
6.1 GREASE LUBRICATED BEARINGS ............................................................................................................. 42
6.2 OIL LUBRICATED BEARINGS .................................................................................................................... 42
6.2.1 Recommended Lubricant ................................................................................................................. 42
6.2.2 Method of Application ..................................................................................................................... 42
6.2.3 Oil Quantity ...................................................................................................................................... 43
6.2.4 Oil Change ........................................................................................................................................ 44
6.3 OTHER LUBRICATION .............................................................................................................................. 47
6.3.1 Packing Box ...................................................................................................................................... 47
6.3.2 Mechanical Seals .............................................................................................................................. 47
7. OPERATION ................................................................................................................................................... 48
7.1 PRIMING .................................................................................................................................................. 48
7.1.1 Priming by Suction Pressure............................................................................................................. 48
7.1.2 Priming by Ejector or Exhauster ....................................................................................................... 49
7.1.3 Priming by foot valve ....................................................................................................................... 49
7.1.4 Priming by Vacuum Pump ................................................................................................................ 49
7.2 STARTUP.................................................................................................................................................. 49
7.2.1 Packing Strips and Packing Gland Tightening Procedure With Flush Lines With Valves ................. 52
7.2.2 Packing Strips and Packing Gland Tightening Procedure With Flush Lines Without Valves or
Without Flush Lines ................................................................................................................................... 56
7.3 OPERATING CHECK.................................................................................................................................. 57
7.4 DOWELING (OPTIONAL) .......................................................................................................................... 58
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Split Case, Centrifugal Pump
7.5 STOPPING ................................................................................................................................................ 59
7.6 SHORT-TERM SHUTDOWN ...................................................................................................................... 60
7.7 LONG-TERM SHUTDOWN ....................................................................................................................... 60
8. MAINTENANCE ............................................................................................................................................. 61
8.1 DISASSEMBLY .......................................................................................................................................... 62
8.1.1 Disasembly Horizontal Pump ........................................................................................................... 62
8.1.2 Disassembly Vertical Pump .............................................................................................................. 64
8.2 INSPECTION AND CLEANING ................................................................................................................... 69
8.2.1 Casing Wear Ring and Impeller Wear Ring Inspection and Replacement ....................................... 69
8.2.2 Vertical Pump Mechanical Seal Maintenance ................................................................................. 69
8.3 REASSEMBLY ........................................................................................................................................... 72
8.3.1 ZW Mechanical Seal – Grease Lubrication Horizontal Reassembly ................................................. 73
8.3.2 ZW Packing Seal – Grease Lubrication Horizontal Reassembly ..................................................... 101
8.3.3 ZW Mechanical Seal – Oil Lubrication Horizontal Reassembly ...................................................... 113
8.3.4 ZW Packing Seal – Oil Lubrication Horizontal Reassembly ............................................................ 113
8.3.5 ZW Mechanical Seal – Grease Lubrication Vertical Reassembly ................................................... 114
8.3.6 ZW Packing Seal – Grease Lubrication Vertical Reassembly .......................................................... 137
8.3.7 Packing Strip Replacement Procedure ........................................................................................... 143
9. SPARE PARTS............................................................................................................................................... 154
10. PARTS INFORMATION ............................................................................................................................... 156
11. TROUBLESHOOTING CHART ..................................................................................................................... 197
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Split Case, Centrifugal Pump
1. PRODUCT DESCRIPTION
These operating instructions contain important information about the installation, operation and service of
the unit. It is therefore imperative that the installing engineer and the responsible specialist/operating
personnel read and understand these operating instructions before installation and commencement of
operation.
This manual must always be available in the operational area of the machine/plant.
IMPORTANT: For any component/accessory that has not been manufactured by Ruhrpumpen and is part of
the pump’s equipment, a complete reading of said component/accessory manufacturer’s manual must be
carried out for further information on proper maintenance procedures and relevant safety warnings.
Correct and orderly installation/assembly is necessary for trouble-free operation of the unit. Ruhrpumpen
does not assume any liability for damage resulting from inadequate installation/assembly. The chosen
location for installation must offer enough space for maintenance activities. Ruhrpumpen recommends
consulting also API Recommended Practices 686 to ensure proper installation in your facility.
Please contact a Ruhrpumpen representative should problems arise. The pump may only be opened by a
Ruhrpumpen approved technician during the guarantee period.
In case of queries, please have your project number and type designation of the pump available. You can
find both of these on the first page of these operating instructions or on the rating plate fixed to the pump.
When ordering spare parts we would further request that you give the description of the required parts,
together with their part numbers and identity numbers. You can find these on the sectional drawing and
spare part list enclosed.
1.1 INTRODUCTION
Ruhrpumpen pumps of type ZW are horizontal, single stage, double suction, single and double volute
axially split case centrifugal pump. These pumps are designed for continuous duty pumping of various fluids
with combinations of metallurgical, mechanical, and installation features.
These pumps rotation can be either clockwise or counterclockwise as viewed from the driver (coupling)
end.
The following information is included in the nameplate of your pump unit:
 Serial number
6

Head

Capacity
V9.100319
ZW
Split Case, Centrifugal Pump

RPM (Rot. Speed)

MAWP – Maximum Allowable Working Pressure

Bearing types (Radial and Thrust/Axial Bearings)
Please quote the pump Serial number when ordering parts; the information in the nameplate is relevant in
some sections of this manual to ensure safe operation of this pump.
1.2 PUMP CASE, IMPELLER, AND WEAR RINGS
1.2.1 Pump Case
Upper-to-lower case fit is machined to receive a confined neoprene cord (O-band).
1.2.2 Impeller and Wear Rings
The impeller is dynamically balanced. Replaceable impeller wear rings are optional.
1.3 BEARING HOUSING
The bearing housings contain a deep groove axial/thrust bearing and a deep groove radial bearing to
positively control all axial and radial forces for smooth low maintenance operation.
1.4 LUBRICATION
Bearings in this pump may be lubricated by grease as standard and oil as an option. Grease lubricated
pump bearings are prelubricated at the factory before shipment. Periodic inspection of bearing lubrication
should be made and additional grease added as needed. Do not overgrease as this causes high bearing
temperatures and shortens bearing life. In pumps with oil lubricated bearings, the bearings are shipped
without oil in the bearing housing.
For more information on bearing lubrication, refer to SECTION SIX - LUBRICATION.
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Split Case, Centrifugal Pump
2. SAFETY
This operation manual gives basic instructions that should be observed during installation, operation and
maintenance of the pump. It is therefore imperative that this manual be read by the responsible
personnel/operator prior to assembly and commissioning. It must always be kept available at the
installation site. Not only are the general safety instructions contained under this SECTION TWO - SAFETY
that must be observed but also the specific information provided in other sections.
2.1 IDENTIFICATION OF SAFETY INSTRUCTIONS IN THE OPERATING MANUAL
Safety instructions given in this manual whose non-compliance would affect personal and equipment safety
are identified by the following symbol.
Where electrical safety is involved, the following symbol is shown.
The
symbol is inserted in safety instructions whenever non-compliance might endanger the
machine or its function.
It is imperative that signs affixed to the machine are observed and kept legible, for example:
•
arrow indicating the direction of rotation
•
symbols indicating fluid connections
2.2 QUALIFICATION AND TRAINING OF OPERATING PERSONNEL
The personnel responsible for operation, maintenance, inspection and assembly must be adequately
qualified. The responsibilities and supervision of the personnel must be exactly defined by the plant
operator. If the staff does not have the necessary knowledge, they must be trained and instructed. Training
may be performed by a Ruhrpumpen representative on behalf of the plant operator. Moreover, the plant
operator is to make sure that the contents of the operating manual are fully understood by the personnel.
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Split Case, Centrifugal Pump
2.3 HAZARDS IN THE EVENT OF NON-COMPLIANCE WITH THE SAFETY INSTRUCTIONS
Non-compliance with the safety instructions may produce a risk to the personnel as well as to the
environment and the unit and results in loss of any right to claim damages.
Non-compliance may involve the following hazards:
•
Risk of injury or death.
•
Failure of important functions of the machine/plant.
•
Exposure of people to electrical, mechanical, chemical, and thermal hazards.
•
Endangering or damaging the environment due to hazardous substances being released.
2.4 COMPLIANCE WITH REGULATIONS PERTAINING TO SAFETY AT WORK
When operating the pump, the safety instructions contained in this manual, the relevant national accident
prevention regulations, local and federal health and safety regulations, quality system requirements, and
any other service and safety instructions issued by the plant operator must be observed.
2.5 SAFETY INSTRUCTIONS RELEVANT FOR OPERATION
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
If hot or cold machine components involve hazards, they must be guarded against
accidental contact (attach warning signs).

Guards for moving parts (e.g. coupling) must not be removed from the machine
while in operation (mounting must be possible only with tools).

Any leakage of hazardous fluids must be drained away to prevent any risk to
persons or the environment. Statutory regulations are to be complied with.

Hazards resulting from electricity must be prevented.
ZW
Split Case, Centrifugal Pump
2.6 SAFETY INSTRUCTIONS RELEVANT FOR MAINTENANCE, INSPECTION AND ASSEMBLY
WORK
It is the plant operator's responsibility to ensure that all maintenance, inspection and assembly work is
performed by authorized and qualified personnel who have adequately familiarized themselves with the
subject in matter by studying this manual in detail.
Any work on the machine shall only be performed when it is at a standstill. To shut off the machine it is
imperative to follow the procedure for shutting down the machine as described in SECTION 7.5-STOPPING.
Pumps and pump units that convey hazardous materials must be decontaminated before any maintenance
work is performed.
On completion of work all safety and protective facilities must be re-installed and made operative again.
Prior to restarting the machine, follow the instructions listed under SECTION 7.2-STARTUP.
2.7 UNAUTHORIZED ALTERATIONS AND SPARE PARTS
Modifications may be made to the machine only after consultation with a Ruhrpumpen representative.
Using spare parts and accessories authorized by Ruhrpumpen is in the interest of safety. The use of parts
not authorized by the dealer exempt the manufacturer from any liability, voiding the warranty.
2.8 UNAUTHORIZED MODES OF OPERATION
The reliability of the machine is guaranteed if and only if it is used in the intended manner, in accordance
with the statutes of this manual. The limit values specified in the data sheet must never be exceeded under
any circumstance.
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Split Case, Centrifugal Pump
3. TRANSPORT & STORAGE
3.1 SHIPPING ARRANGEMENTS
IMPORTANT NOTICE
1.
Motor may be shipped mounted on the baseplate alongside the pump or loose, at the factory’s
discretion. This will be considered on a case by case basis depending on the potential effect on
the baseplate’s design, weight distribution and risks of improper lifting and/or handling of the
equipment.
2.
If, by customer request, it is necessary that all components be mounted on the baseplate during
shipping, this must be notified to Ruhrpumpen during the quoting process, as this requires an
analysis and design of a special, customized baseplate.
3.
If during the quoting process the customer fails to notify Ruhrpumpen the request that all
components be forcibly mounted on the baseplate during shipment, Ruhrpumpen may ship all
components mounted on the baseplate, prior written request from the customer, under the
customer’s responsibility of the risks of deformation during transport.
A wooden skid is furnished for support and ease of transportation. Other required items (e.g. coupling,
hardware, spare parts, etc.) are boxed or secured to the skid.
3.2 UNLOADING AND CHECKING EQUIPMENT
NOTE: The information portrayed in this section is intended as a general guideline. For further information
refer to the corresponding section in API Recommended Practices 686.
The following steps should be completed for all pumps when received.
1. Handle all equipment carefully.
2. Remove unit only by properly supporting the wooden shipping skid.
3. After unloading, inspect the pump, check the shipment against the packing list, and report damages
or shortages immediately to freight carrier and to the designated Ruhrpumpen representative.

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Do not place lifting rig around bearing frame or under baseplate. Do not use the
lifting lugs on the upper half casing to lift unit.
ZW
Split Case, Centrifugal Pump
3.3 TRANSPORT

To avoid damage, the unit must be transported and handled with care. It should
be gently lowered onto an even surface. Pay attention to and identify the signs
marking the points of equilibrium and fastening places for ropes, or the openings
for forklift trucks.

Observe the plant’s safety precautions when lifting heavy components.

When transporting with a crane, the rope should be slung round the whole
baseplate, as shown in Figure 3.1.

The rope should not be slung around the lugs attached to the motor or around
the lugs attached to the pump. When lifting the bare shaft pump only, please
position the ropes as shown in Figure 3.2.
Figure 3.1a Correct position of the lifting ropes or chains, side and non-drive end view, horizontal pump.
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Split Case, Centrifugal Pump
Figure 3.1b Correct position of the lifting ropes or chains, front and side view, vertical pump.
Figure 3.2 Correct position of the pump lifting – bare shaft pump only.
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Split Case, Centrifugal Pump
3.4 STORING
If the pump is not installed immediately (within one month after shipping date), it should be safely stored
prior to installation in a dry location free of dirt and grit. Furthermore, the pump unit (pump, driver, etc.)
should not be subject to sudden temperature changes or vibrations.
Observe the following steps:
1. Remove pump from shipping crate, but do not damage the crate because the unit is to be reboxed.
2. Remove all instruments and mechanical seal; store them safely.
3. Plug the instrument taps.
4. Thoroughly dry the pump with hot air.
5. Any painted surface damaged in shipment should be repainted or sprayed with oil.
6. Keep the pump moisture-free by the following two means:
a. Spray the pump case with acid-free, moisture-free, protective oil or kerosene.
b. Place desiccant or humidor bags inside the suction and discharge areas of the pump.

Attach red tags with a “Remove Moisture Absorbent Material Bags Prior to
Installing” to warn about the presence of this desiccant material.
7. Cover all the openings with plywood or metal covers. Recheck the condition of these covers every
month and replace as necessary.
8. Since oil lubricated pumps are shipped without oil in the bearing housing, fill the bearing housing
with oil according to SECTION SIX – LUBRICATION. Bearing oil must be inspected periodically and
changed every six months or as necessary during the storage period.

Always drain the oil before moving the pump, to avoid any damages, and refill
the bearing housing on its new location.
9. If the pump’s external parts have protective coatings, periodically inspect and renew the coating as
required.
10. Rotate the shaft 1 ¼ revolutions every week. Lubricate shaft bearings prior to rotation.
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Split Case, Centrifugal Pump

The client must keep a record of the weekly rotation of the shaft. Failure to
document and present these records as evidence will void the warranty.
11. Check the packaging for damage every month.
12. Ensure pump flange covers remain in place.
13. Return the unit to the shipping crate.
14. When the pump is to be installed, remove all the protective coatings and desiccant or drain all oils.
One month before installation, a Ruhrpumpen representative should be employed to conduct a final
inspection.
To properly store the motor (driver) for periods longer than one month, follow these steps:
1. Store the motor in a clean, dry area, or cover it with a loose tarp (the tarp must be loose in order to
prevent condensation).
2. Exercise precautions to avoid transit or nesting of rodents, snakes, birds, and insects.
3. Inspect and, if necessary, recoat the rust preventive coating of external machined surfaces.
4. Fill with lubricant the grease-lubricated cavities of the motor, but first remove the drain plug and fill
the cavity until the grease starts to purge.

Follow the instruction manual of the driver manufacturer to ensure the
lubrication is performed properly.
5. Upon receipt, considering that the oil-lubricated drivers are not shipped oil-filled, fill the reservoir to
maximum level with properly selected oil with rust and corrosion inhibitors.

Always drain the oil before moving the pump, to avoid any damages, and refill
the motor on its new location.
6. Rotate the shaft of the motor once a month.
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Split Case, Centrifugal Pump
7. Some form of heating must be used to prevent condensation. This heating should maintain the
winding temperature at a minimum of 9 °F (5 °C) above the surrounding ambient temperature.
There are three options:
o If space heaters are supplied, they should be energized.
o If none are available, single phase or “trickle” heating may be utilized by energizing one
phase of the motor’s windings with a low voltage, producing heat in the winding conductor.

Request the required voltage and transformer capacity from the driver
manufacturer.
o A third option is to use an auxiliary heat source and keep the windings warm by either
convection or blowing warm dry air into the motor.

Be careful not to overheat, since keeping the temperature of the motor frame
9 °F (5 °C) above the surrounding ambient temperature is sufficient.
After the storing period, follow the next steps as start-up preparations:
1. Motor should be thoroughly inspected and cleaned to restore to an “As Shipped” condition.
2. Motors, which have been subjected to vibration, must be disassembled and each bearing inspected
for damage.
3. Oil and/or grease must be completely changed using lubricants and methods recommended on the
motor's lubrication plate, in the “LUBRICATION” section of the driver manufacturer’s manual.
4. If storage has exceeded one year, the motor manufacturer’s Quality Assurance Department must be
contacted prior to equipment start-up for any special recommendations.
3.5 CONSERVATION
All exposed, machined, working surfaces (flanges, seals, surfaces supporting the motor), shaft ends,
unpainted couplings and the like have been cleaned and treated with anticorrosive agents. After being
cleaned, all parts inside the pump housing have been sprayed with anticorrosive agents.
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Split Case, Centrifugal Pump
The period of protection offered by these conservation measures is approximately 18 months if stored in a
dry place. If stored under unfavorable climatic conditions, this protective period may be considerably
reduced. Should the anticorrosive layer become damaged, it can be repaired by repainting or respraying.
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
Anticorrosive layers inside the pump housing must be removed with process
neutral solvents before commencing pump operation.

When removing the protective coating with a neutral solvent, follow the safety
instructions of the solvent manufacturer carefully.

The anticorrosive layer applied to the exposed parts does not need to be
removed before putting the pump into operation.
ZW
Split Case, Centrifugal Pump
4. INSTALLATION
Correct and orderly installation/assembly is necessary for trouble-free operation of the unit. Ruhrpumpen
does not assume any liability for damage resulting from inadequate installation/assembly. The chosen
location for installation must offer enough space for maintenance activities. Ruhrpumpen recommends
consulting also API Recommended Practice 686 to ensure proper installation in your facility.
4.1 CONCRETE FOUNDATION PREPARATION
NOTE: The information in this section is intended as a general guideline. For further information refer to
the corresponding section in API Recommended Practices 686.
IMPORTANT: The design of foundations is not the responsibility of Ruhrpumpen. It is therefore
recommended that the customer consult a competent specialist skilled in the field of foundations, to insure
proper design/installation of the foundation.
1. Choose a solid ground location for foundation; check that the bearing capacity of the soil is at least
one third higher than both static and dynamic loads together.
2. The effects of vibrating equipment on the surrounding area should be investigated and the isolation
required for the foundation should be considered. It is important to consider that the driver and the
driven machinery must be supported from a common foundation.
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
All foundation materials shall be selected to prevent deterioration due to
exposure to an aggressive environment; the use of a protective coating should be
considered.

The mass of the concrete foundation should be five (5) to ten (10) times the mass
of the supported equipment.

Imaginary lines extended downward 30 degrees to either side of a vertical line
through the pump shaft should pass through the bottom of the foundation and
not the sides, as shown in Figure 4.1.
ZW
Split Case, Centrifugal Pump
30°
30°
Figure 4.1. Imaginary lines.
3. It is recommended to build foundation approximately 3 inches (76 mm) larger overall than the
pump baseplate to provide ample anchorage for the foundation bolts.
3.1.
Since water can accidentally flow in the floor, a height for the surface of the foundation of 4
inches (100 mm) at least above floor level is recommended.
4. Use a template to accurately locate foundation bolts according to the General Arrangement.
4.1.
Choose foundation bolts of size specified in drawing (ASTM A36, M 1020 and ASTM A575 are
recommended); they should be long enough to allow a minimum of two threads above the
nuts.
5. Provide pipe enclosures for the bolts, which are three or four diameters larger than the bolts.
6. Protect area around the bolts from contact with the concrete.
7. Pour the concrete and provide a chamfer at all corners.
8. Allow concrete to cure completely (at least seven days) before preparing the surface for grout
preparation.
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Split Case, Centrifugal Pump
4.2 LEVELING BASEPLATE
NOTE: The information included in this section is intended as a general guideline. For further information
refer to the corresponding section in API Recommended Practices 686.
Before leveling the unit onto the foundation, the following preparations must be made:
1. Chip away all damaged concrete with a hammer and chisel, eliminating about one inch of the
surface of the foundation. After surface chipping is done, the foundation shall be thoroughly
cleaned free of debris. Clean the anchor holes.
2. Check that the placement and dimensions of the foundation and the anchor holes correspond to the
assembly plan.
The foundation must be kept free of all contamination after it has been prepared for grouting.
To continue with the leveling procedure:
1. Remove the pump and driver from the base to facilitate the leveling procedure. This will facilitate
the next steps and prevent distortion of the baseplate.
2. If alignment is to be performed with wedges, place steel blocks and wedges (or shim packs) as
closely as possible to the foundation bolts.
3. Remove baseplate from wooden skid.
4. Attach lifting rig hooks to lifting holes of baseplate as described in SECTION 3.3-TRANSPORT.
5. Guide baseplate to position above foundation bolts and lower baseplate into position over
foundation bolts; be sure to respect the above-mentioned clearance between concrete and
baseplate.
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
There should be a minimum annular clearance of 1/8 inch (3 mm) between
anchor bolt holes and the anchor bolts to allow for field alignments.

Exercise proper caution when working under or around suspended objects.
ZW
Split Case, Centrifugal Pump
6. If baseplate has preparation for jacking bolts, using a precision level across baseplate pads, adjust
jacking bolts as necessary. Otherwise, adjust wedges (shim packs) as necessary using a precision
level across baseplate pads. Ensure that baseplate is level in all directions (See Figure 4.2); leveling
within 0.002 in/ft (0.2 mm/m) is recommended. Wedges or shim packs should feel solid when
tapped lightly by a hammer.
Figure 4.2. Baseplate leveling planes

The alignment of the baseplate is effected with the help of adjusting screws, or
wedges, depending on the preparation of the baseplate.

NOTE: When using jacking bolts, each one should have a mounting pad, to
distribute the stresses evenly.

NOTE: The baseplate should be mounted without distortion.
7. When baseplate is level, 'snug' the foundation bolt nuts, but do not tighten completely.
4.3 GROUTING*
NOTE: The information included in this section is intended as a general guideline. For further information
refer to the corresponding section in API Recommended Practices 686.
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IMPORTANT: It is recommended that the customer consult a competent specialist skilled in the field of
grouting to insure proper installation of all grouting.
4.3.1 Equipment/Material Required
•
Grout Mix: Non Shrink Type.
•
Sufficient lumber for foundation template and grout trough.
•
Risers or funnels for guiding grout.
•
Sufficient oil paint for grout protective covering.
•
Dial indicator.
•
One bracket, suitably stiff having an arm length of sufficient length to extend from the driver
coupling hub to the pump coupling hub.
4.3.2 Grouting Precautions
During all the grouting process, the involved personnel must follow these safety precautions:
1. Wear goggles or face shields, aprons, and protective gloves at all times.
2. Wear dust masks if in contact with the dry aggregates.
3. Wash hands regularly with soap and water.

Some epoxy grouts have highly exothermic reactive properties; they should be
handled with care. They may become extremely hot and cause severe burns.
4.3.3 Grouting Procedure
1. Verify that anchored bolt sleeves are clean and dry. Fill them with a nonbonding moldable material
to prevent them from being grouted.
2. The anchor bolt threads should be protected with tape before grouting.
3. Provide a form around the baseplate to contain the grout. The form should be chamfered at all
corners.

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Grout forms should be attached with drilled anchors. Do not power nail.
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Split Case, Centrifugal Pump

Apply three coats of paste wax to the inside surfaces of the forms in order to
prevent adherence. Do not use oil or liquid wax.

Prevent grout leakage, as leaks will not self-seal.
4. Apply the grout. The use of push tools to get rid of trapped air is allowed if done in long strokes.

Do not vibrate or violently ram the grout (it may cause the aggregates to
separate).

Do not plug any baseplate fill or vent holes until the grout has set to avoid
baseplate distortion.

Check with the supplier of the grout the preferred thickness for your installation.
5. Tap baseplate to eliminate air pockets.

It is imperative to get rid of all trapped air before the grout hardens.

Check frequently for grout leaks.

Leaks will not self-seal and may cause voids.
6. If jackscrews (jacking bolts) were used, remove them and grout-forms once the grout has
completely hardened (takes around 3 days).
7. Do not use grout to fill the jackscrew’s holes; use a sealant material instead.
8. Tighten the foundation bolts with an appropriate torque value. In case of doubt, please contact your
Ruhrpumpen representative.
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9. Apply oil paint to exposed grout to protect from air and moisture.
10. Use a lifting rig to position the pump and driver on their baseplate so that the mounting feet line up
with their respective tapped holes.
11. Fasten the pump and driver hold down bolts, attach all auxiliary piping and wiring.

NOTE: *If by client specification the pump is to be used in a service where
grouting will not be possible, for example fire duty, it is responsibility of the
customer to use a PIP baseplate. Otherwise, please note that baseplates are not
pre-grouted, therefore this grouting procedure shall be followed by the
customer.
4.4 PUMP VERTICALIZATION
4.4.1 Vertical Pump Unmounting
1. Stop the pump. See SECTION 7.5 - STOPPING.
2. Drain all possible fluids from the pump case and bearing houses.
3. When disassembling the pump, match mark, tag or otherwise identify all parts, and provide
separate containers for small parts. Refer to the sectional drawing of the pump included in SECTION
TEN - PARTS INFORMATION for the correct identification of the parts.
4. Disconnect any auxiliary piping and wiring that could interfere with disassembly.
5. Remove the coupling guard.
6. Loosen the screws that secure the motor coupling hub to the shaft.
7. Slide the coupling hub up to separate the coupling between the motor and the pump.
8. Secure the motor coupling hub in the new (temporary) position with the screw to the shaft.
9. Secure or remove the motor shaft key.
10. Remove the coupling intermediate element (spacer).
11. With the help of a crane and slings, secure the motor so that it will not tilt during the removal of the
screws that fix it to the motor support.
12. Untighten and remove all the screws that fix the motor to the vertical frame.
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13. Using a crane and slings, remove the motor from the vertical frame and place it on a horizontal
surface. Make sure that the motor is in a stable position; the shaft end should not touch any
bounding surfaces.

Make sure to protect the electric motor shaft when removing the motor from the
vertical frame and/or in the process of installing it on the support. In case of
dismantling the coupling hub from the motor shaft, it is recommended to install
protection for the motor shaft end (guard), which is supplied with the motor.
14. Untighten and remove the corresponding bolts and washers that fix the top plate with motor
support to the back and front support columns.
15. Using a crane and slings, remove the motor plate and place it on a horizontal surface.
16. DO NOT REMOVE the studs and nuts that secure the lower pump casing to the front support
columns.
17. Place soft slings around the suction and discharge nozzles of the pump and secure them onto the
crane hook. Gently tighten the slings so that they only hold the pump during the further dismantling
of the pump feet bolts.
NOTE: it is also recommended to place a wooden beam under the lower legs of the pump to ensure the
position of the pump when it is removed from the vertical frame.
18. Untighten and remove the corresponding bolts that fix the front support columns to the lower base.
19. Remove front support columns from the lower base.
20. Untighten and remove the bolts that fix pump feet to the back columns.
21. Using the crane and the slings attached around the pump´s suction and discharge flanges, carefully
separate the pump from the vertical frame. DO NOT ROTATE the pump to its horizontal position.
22. Place the pump on a horizontal surface, placing a wooden beam under the pump feet. The pump
will also rest on the two unmounted front columns.
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4.4.2 Vertical Pump Mounting
1. Place slings around the pump´s suction and discharge flanges. Gently tighten the slings to a firm
grip.
2. Using a crane and the slings placed on the previous step, carefully lift the pump and place it on the
vertical frame.
3. Place and tighten the corresponding bolts that fix the pump feet to the vertical frame´s back
columns.
4. Place the front support columns on the lower base.
5. Place and tighten the corresponding bolts that fix the front support columns to the lower base.
6. Using a crane and slings, lift the motor plate and place it on top of the vertical frame´s back and
front support columns.
7. Place and tighten the corresponding screws that fix the motor to the motor plate.
8. Place the coupling intermediate element (spacer).
9. Place the motor shaft key.
10. Untighten the screw that fixes the coupling hub on its position on the shaft.
11. Slide the coupling hub down to secure the coupling between the motor and the pump.
12. Tighten the screws to secure the motor coupling hub to the shaft.
13. Place the coupling guard.
14. Connect all auxiliary piping and wiring.
15. Start the pump. See SECTION 7.2 – STARTUP.
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5. PIPING AND ALIGNMENT
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
These units are furnished for a specific service condition. Any change in the
hydraulic system may affect the pump performance adversely.

The connection of the piping must be carried out with utmost care; otherwise,
the pumping medium can escape during operation, which can seriously endanger
the operating personnel.

Do not start the piping and alignment procedures until grouting, preliminary
alignment (as seen in the previous sections of this manual) and on site welding
have been performed.

In a new installation, great care should be taken to prevent dirt, scale, welding
beads, and other items from entering the pump. The suction system should be
thoroughly flushed before installing the suction strainer and suction piping.

Suction and discharge piping should be of ample size, be installed in direct runs
with minimum bends.

Short radius elbows shall be avoided near the suction nozzle. If an elbow is
necessary, it should be of the long radius type.

Suction and discharge piping conFiguretions should be in accordance with the
Hydraulic Institute Standards.

Suction and discharge piping, fittings, and valves must be adequately supported
and anchored close to the pump flanges to eliminate strains imposed on the
pump case, prevent excessive nozzle loads, maintain pump/driver alignment, and
avoid pipe-induced vibration.
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Split Case, Centrifugal Pump
5.1 PIPING THE SYSTEM
NOTE: The information included in this section is intended as a general guideline. For further information
refer to the corresponding section in API Recommended Practices 686.
IMPORTANT: The design of piping and related systems is not the responsibility of Ruhrpumpen. It is,
therefore recommended that the customer consult a competent specialist skilled in the field of piping to
insure proper design/installation of all the piping.
1. Check whether the piping is loosely laid, so that no strain is placed on the pump.

Piping layout and installation shall provide adequate maintenance and operation
accessibility. Field installed auxiliary equipment shall not interfere with removal
of the machine or driver.
2. Remove the covers of the pump flanges.
3. Check whether the seals are correctly mounted.
4. Install a check valve and a gate valve in the discharge pipe. When the pump is stopped, the check
valve will protect the pump against excessive back-flow pressure and will prevent the pump from
running backward.

The check valve should be installed between the gate valve and discharge flange
in order to permit its inspection.
5. A spool piece should be installed in suction line so that the suction strainer may be installed and
removed with a pressure gauge between the strainer and pump.
6. The suction strainer should be installed between 5 to 20 pipe diameters upstream from the suction
flange.
7. Cone type strainers (otherwise known as “witches–hat” strainers) should be mounted as
recommended by the Hydraulic Institute, that is, with the cone pointing upstream away from the
pump, into the oncoming flow. As the strainer gradually gathers particles from the liquid and blocks
up, this direction will result in the lowest turbulence impact onto the liquid flow entering the pump.
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Figure 5.1. Proper installation of conical strainer
8. Disconnect the piping from the pump if you heat one side of the pipe to align the pipe to the pump.
9. Pump and pipe flanges must be parallel; they should mate together without effort, and with the
bolt holes properly in line.
10. Check the fine alignment by clocking or using a Dial Type Indicator (DTI) on the coupling. Check the
operating instruction for the coupling.
11. Connect and tighten the suction pipe and compare the alignment with the values of the fine
alignment. In the case of deviations, warm the pipe so that the values of the fine alignment are
reached.

When heating takes place close to the flange, there is a danger that the flange
seal will become rippled and leaky. No more welding work can be carried out on
the piping when it is screwed to the pump.
12. Proceed in the same way with the discharge pipe.
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
Make sure that there are isolation block valves at the pump for each type of
auxiliary piping.

Consider a slope in the suction piping to avoid high points.
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
In horizontal suction lines, reducers should be eccentric (with the flat side of the
reducer on top).

No obstruction within at least five pipe diameters of the suction flange should be
fitted.

Do not install unsupported piping on the pump.

Make sure electrical connections do not impose any stress on the pump unit.

Remember that the pump must not be moved once the baseplate has been set:
the piping (both suction and discharge) is the one aligned to the pump.

When aligning, all the elements to be aligned (including the pipes) should be at
the same temperature (ambient).

It is important to confirm that the pump can be moved out from the baseplate
without cutting or welding (only by adjusting connections and flanges).

Do not use drifts or cheater bars to force alignment of bolt holes – serious
damage to the pump will result.
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Split Case, Centrifugal Pump
5.2 HORIZONTAL ALIGNMENT
NOTE: The information included in this section is intended as a general guideline. For further information
refer to the corresponding section in API Recommended Practices 686.
In the following pages, alignment procedures are explained with dial indicators. Laser alignment is also
possible. The specific method in laser alignment will depend on the manufacturer’s instructions; however,
the basic principles and rotation of the shafts apply, as in the Reverse Indicator Alignment Method.
Therefore, for laser alignment, you may follow the steps detailed on the next pages, mounting a laser
bracket with a measurement device on each shaft and then proceed with the rotation of the shafts to
obtain the readings to determine the misalignment and correct it.
A. ALIGNMENT OF EQUIPMENT
Correct alignment is mandatory for the successful operation of rotating equipment. A flexible coupling is no
excuse for misalignment. The relationship between shaft centerlines can easily be determined by 1) two
step dial indicator method, 2) reverse indicator alignment, 3) across the disc pack alignment. These can all
be solved by a graphical approach. This procedure will discuss methods 2 and 3. Before we get into this
alignment procedure, several items should be considered at this point.
1. Indicator Set-Up
No matter what arrangement you use, indicator sag must be determined. This can easily be determined by
clamping the set-up onto a rigid piece of pipe, rolling the indicator from top to bottom, and reading the
difference. Once the indicator sag set-up has been determined, this number can be algebraically subtracted
from the alignment readings obtain at the bottom. There is no need to be concerned about the side to side
readings as the sag is equal on both sides.
2. Taking Alignment Readings
It is suggested that the dial indicator be zeroed at the top. For convenience, you should mark your coupling
at 0°, 90°, 180°, and 270° with a reference mark on the case so that you can be sure to turn the unit exactly
90°. Both shafts should be turned an equal amount if the coupling is not put together. Now rotate the
coupling in 90° increments recording all readings. It is important to keep your side to side readings straight.
A suggestion is to show compass orientation so that you know which reading to use. After you have made
your four position check and have returned back to the top, it is absolutely necessary that the indicator
return to zero where it started. If it did not, repeat your readings. It is also advisable to check the readings
several times to make sure that they are repeatable.
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3. Thermal Growth
If there are thermal growth considerations on the piece of equipment, it is a good idea to get these
numbers so that they can be added to or subtracted from the graphical solution before the equipment
move is made, this is known as “Hot alignment”.
4. Soft Foot
The fact that your equipment could have a soft foot can affect the alignment readings that you obtain. The
soft foot should be checked first and eliminated. This can easily be done by mounting a dial indicator on the
base plate indicating off the top of foot on the machine to be checked. Each foot in rotation is then checked
by loosening only the bolt with the rest of the bolts being tight. A soft foot check should be carried out
when the unit is stationary for safety reasons, and should be carried out on whole drive train. It should
never be necessary to shim under the pump mounting feet. Soft foot issues could indicate excessive piping
loads transmitted to the pump, or that the baseplate has been twisted, and is not grouted and mounted
flat.
B. REVERSE INDICATOR ALIGNMENT GRAPHICAL ANALYSIS
On a sheet of graph paper, lay out the equipment that you are trying to align. You should use a scale that is
convenient to the size of the graph paper. The distances that are critical are:
32
1.
Distance from where the first indicator rides on the pump hub to where the second indicator
rides on the motor hub. In the example shown below, this is 10-1/2 inches (266.7 mm).
2.
Distance from where the second indicator rides on the motor hub to the center of the front
motor feet. In the example below, this is 2-1/2 inches (63.5 mm).
3.
Distance from the center of the motor front feet to the center of the motor back feet. In the
example shown below, this is 5-1/4 inches (133.4 mm).
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Split Case, Centrifugal Pump
Figure 5.2. Example for reverse indicator graphical analysis.
The next step is to determine indicator sag. Set up your bracket arrangement on a pipe. Set the indicator at
'0' on top. Roll set up until indicator is at the bottom of pipe. It will read negative. In this example, it is
found to be -0.005 inch (-0.127 mm).
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Figure 5.3. Indicator sag.
With the indicator bracket attached to the motor hub reading off the pump hub, rotate unit in 90°
increments and take readings.
Bottom reading is then corrected for indicator sag. Indicator sag in the example was determined to be 0.005 inch (-0.127 mm). The -0.005 inch (-0.127 mm) was subtracted from the -0.025 inch (-0.639 mm)
indicator reading to give an actual -0.020 inch (-0.508 mm) reading.
As this is a TIR (Total Indicator Readout) it is two times the actual shaft to shaft rotation 0.020 inch (0.508
mm)/ 2 inch (50.8 mm) or 0.010 inch (0.254 mm) is used to show where the motor shaft extension is
relative to the pump shaft center line at the hub. Minus at the bottom indicated motor shaft extension is
low compared to the pump. Using a scale of one small division on the graph equals 0.001 inch (0.0254 mm);
plot this point as show in the example.
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Split Case, Centrifugal Pump
Figure 5.4. Motor shaft extension relative to the pump shaft center line.
Now with the indicator bracket attached to the pump hub reading off the motor hub, rotate unit again in
90° increments. NOTE: If you can set up both indicators at once, both sets of readings can be taken at one
time.
Bottom reading is then corrected for indicator sag. The -0.005 inch (-0.127 mm) was subtracted from the
+0.005 inch (+0.127 mm) indicator reading to give an actual +0.010 inch (+0.254 mm) reading.
The +0.010 inch (+0.254 mm) is divided by two to give +0.005 inch (+0.127 mm) which is the actual shaft
extension to shaft relationship.
In this case, a plus reading at the bottom indicates the motor shaft is low compared to the pump shaft
extension. Plot this point as shown in the example.
Figure 5.5. T.I.R. second reading
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We have now located the motor shaft theoretical extension in two places:
A. In the plane of the pump hub.
B. In the plane of the motor hub.
Drawing a straight line through these two points crossing the plane of the two motor feet. The shim
adjustment can now be read directly off the graph. In this example, 0.004 inch (0.102 mm) should be added
to the front foot and 0.001 inch (0.025 mm) should be added to the back foot.
This solution can also be done by the use of pre-programmed, hand calculators for faster results.
For the horizontal (side to side) results, the same procedure is used. Algebraically subtract the side to side
readings. Indicator sag can be ignored as it cancels out. Plot these readings and the results can be read off
the graph plot.
Figure 5.6. Final graph plot for reverse indicator alignment graphical analysis.
C. REVERSE INDICATOR ALIGNMENT MORE THAN TWO UNITS GRAPHICAL ANALYSIS
This method lends itself very well in solving alignment problems of three or more pieces of equipment in a
line.
To solve this problem, follow the steps already outlined for each coupling in the train. Plot the shaft to shaft
relationship of each set of shafts. Look at the total picture. In this example, a line was drawn through the
average of all points plotted. The units were then aligned to this mean line.
Figure 5.7. Reverse indicator alignment of more than two units.
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D. ACROSS THE DISC PACK ALIGNMENT GRAPHICAL ANALYSIS
When the distance between disc packs is long where it is not practical to try to span the distance with
indicator bracketry, the 'across the disc pack method' can be used.
On a sheet of graph paper, lay out the equipment that you are trying to align. You should use a scale that is
convenient to the size of the graph paper. The distances that are critical are:
1.
Distance from centerline of one disc pack to the centerline of the other disc pack. In the
example, it is 9-1/2 inches (241.3 mm).
2.
Distance from centerline of motor disc pack to center of front motor foot. In this example, it is
3 inches (76.2 mm).
3.
Distance from the center of the motor front feet to the center of the motor back feet. In this
example, it is 5-1/4 inches (133.4 mm).
4.
Distance from disc pack to dial indicator on center member. In this example, the distance is
8 inches (203.2 mm).
Figure 5.8. Across the disc pack alignment graphical analysis example.
The next step is to determine indicator sag. Set up your bracket arrangement on a pipe. Set the indicator at
'0' on top. Roll set up until indicator is at the bottom of pipe. It will read negative. In this example, it was
found to be -0.004 inch (-0.102 mm).
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Split Case, Centrifugal Pump
Figure 5.9. Indicator sag in across the disc pack alignment analysis example.
With the indicator bracket attached to the pump hub, reading out the center member a convenient
distance, (in this example 8 inches [203.2 mm] was used) rotate the unit in 90° increments and take
readings.
Bottom reading is then corrected for indicator sag. The indicator sag in the example was determined to be 0.004 inch (-0.102 mm). The -0.004 inch (-0.102 mm) was subtracted from -0.025 inch (-0.635 mm)
indicator reading to give an actual of -0.020 inch (-0.508 mm) reading.
As this is a TIR (Total Indicator Reading) it is two times the actual center member center line location
relative to the pump shaft extension or -0.020 inch (-0.508 mm) / 2 inches (50.8 mm) = -0.010 inch
(0.254 mm). (What we are trying to do here is to determine the angle the center member makes with
respect to the pump shaft.)
A plus reading at the bottom indicates that the center member tips down as it extends away from the
pump. Using a scale of one small division on the graph equals 0.001 inch (0.0254 mm); plot the 0.010 inch
(0.254 mm) as shown in the example.
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Split Case, Centrifugal Pump
Figure 5.10. Plot of the plus reading in the across the disc pack alignment analysis example.
Now with the indicator bracket attached to the motor hub reading out on the center member, rotate the
unit in 90° increments and take readings.
Bottom reading is corrected for indicator sag: ±0.008 inch (±0.203 mm) -0.004 inch (0.102 mm) =
+0.012 inch (+0.309 mm). This is TIR so actual is +0.006 inch (+0.152 mm). (What we are trying to do here is
determine the angle the center member makes with respect to the motor shaft.)
The minus reading on the bottom indicates that the center member tips up as it extends away from the
motor. Using a scale of one small division on the graph equals 0.001 inch (0.025 mm), plot the 0.006 inch
(0.192 mm) as shown on the example.
The motor shaft can now be drawn in because two points along it have been defined: 1. Center of the flex
element. 2. The point just plotted 0.006 inch (0.152 mm) below center member. The shimming
requirements can now be read off the plot where the motor shaft intersects the planes of the motor feet.
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Split Case, Centrifugal Pump
Figure 5.11. Plotting the motor in the across the disc pack alignment analysis example.
In this example, the motor should be shimmed up 0.013 inch (0.330 mm) under front feet and shimmed up
0.016 inch (0.406 mm) under back feet.
This solution can also be done by use of a pre-programmed, calculator for faster results.
For the horizontal (side to side) results, the same procedure is used. Algebraically subtract the side to side
readings. Indicator sag can be ignored as it cancels out. Plot these readings and the results can be read off
the graph.
5.3 DRIVE SHAFT PUMP ALIGNMENT
If your pump is furnished with a drive shaft, refer to the manufacturer´s manual for the correct alignment
procedure.

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Baseplates for pumps that are equipped with drive shafts are fully prepared,
according to the driver manufacturer´s specifications, to accept the drive shaft.
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Split Case, Centrifugal Pump
5.4 VERTICAL ALIGNMENT
Alignment between the motor stool and the pump casing can be achieved by adding or removing shims
between them. Horizontal mobility at the interface between the motor and the motor stool assembly is
also provided, as required.
Angular alignment between the motor stool and the vertical frame is also carried out by adding the
correctly sized shims between them.
It must be noted that if the motor to motor stool fit is of the spigot (rabbet) kind, no horizontal movement
is achievable at the interface.
NOTE: Jackscrews are added at the interface if there is a need to perform a horizontal alignment caused by
tolerance differences between the motor stool spigot and the motor´s flange.
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6. LUBRICATION
6.1 GREASE LUBRICATED BEARINGS
Grease lubricated pump bearings are prelubricated at the factory before shipment. Periods of subsequent
lubrication depend on local conditions, loads, speeds, hours of operation, and temperature.
Periodic inspection of bearing lubrication should be made and additional grease added as needed. At this
time, the plug in the bottom of the bearing cover should be removed and the bearing flushed with clean
grease. A Chevron SRI-2 or Shell Dolium “R” Grease is recommended for most installations. Do not
overgrease as this causes high bearing temperatures and shortens bearing life. The pump should be run a
short time to eject any excess grease and the plug then replaced in the bearing cover.
6.2 OIL LUBRICATED BEARINGS
6.2.1 Recommended Lubricant
The recommended bearing frame oil is ISO VG 68 non-detergent oil. Turbine quality oil is preferred. This oil
may be used during break-in and normal operation.
6.2.2 Method of Application
Customer must fill bearing frame before startup. Fill the bearing frame with oil according to the quantities
specified in the next section.
Please refer to the steps indicated in Section 6.2.4 - Oil Change for instructions on how to fill the bearing
housings with oil.

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Ruhrpumpen takes every precaution during our assembly process and
subsequent final assembly audits to ensure no bearing frame oil leaks exist prior
to shipment. Oil can leak past the lip or labyrinth seal in an “overfill” condition.
Refer to the filling instructions for additional information.
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Split Case, Centrifugal Pump
6.2.3 Oil Quantity
The combined quantity of initial fill for bearing bracket and oiler is:
Series
Oil quantity
Quarts
L
50
0.29
0.28
60
0.45
0.43
70
0.54
0.51
80
1.01
0.96
100
1.28
1.21
120
0.78
0.74
150
1.62
1.53
175
3.10
2.93
Additional oil consumption, under normal operating conditions, is replenished by the constant level oiler.
The pump sizes that correspond to each series are as follows. If you do not find your pump size or have any
doubt or question regarding oil quantity required, please contact your Ruhrpumpen representative for
clarification as needed.
Series 50:
6x4x8
5 x 4 x 10
6 x 4 x 10
6 x 4 x 12
8 x 6 x 13
10 x 8 x 13
6 x 4 x 14
8 x 6 x 15
Series 60:
8x5x8
8x6x8
10 x 8 x 8
6 x 5 x 10
8 x 5 x 10
8 x 6 x 10
10 x 8 x 10
6 x 5 x 12
8 x 5 x 12
8 x 6 x 12
10 x 6 x 12
12 x 8 x 13
6 x 5 x 14
8 x 5 x 14
8 x 6 x 14
10 x 6 x 14
6 x 4 x 16
8 x 5 x 16
8 x 6 x 16
10 x 8 x 16
10 x 6 x 19
8 x 6 x 19.5
12 x 10 x 13
12 x 10 x 16
10 x 8 x 19
10 x 8 x 23
Series 70:
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Series 80:
14 x 12 x 14
14 x 10 x 16
12 x 8 x 19
12 x 10 x 20
12 x 8 x 24
10 x 8 x 27
Series 100:
16 x 12 x 17
18 x 14 x 17
18 x 14 x 20
20 x 14 x 20
12 x 10 x 24
14 x 10 x 24
12 x 10 x 29
Series 100-Alfa:
16 x 12 x 20
Series 120:
20 x 16 x 21
24 x 18 x 22
16 x 12 x 23
16 x 12 x 25
24 x 18 x 25
14 x 10 x 29
16 x 12 x 30
20 x 16 x 30
20 x 16 x 36
Series 150:
24 x 18 x 23
26 x 20 x 26
26 x 20 x 30
30 x 24 x 31
24 x 18 x 37
20 x 16 x 44
26 x 20 x 37
24 x 18 x 45
26 x 20 x 45
Series 175:
6.2.4 Oil Change
Once every eight hours of pump operation, perform visual inspection of oil and oil level in constant level
oiler.
The first oil change should be carried out three weeks after commissioning; all further oil changes take
place every six months. However, replenish oil as necessary if oiler empties
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
Only change the oil when the machine is switched off.

The drained oil is hot, and can cause severe burns.
ZW
Split Case, Centrifugal Pump
Refer to SECTION 6.2.1 - Recommended Lubricant for recommended oil types and to SECTION 6.2.3 - Oil
Quantity to ensure the proper quantity according to the bearing bracket size of your pump.
The oil change should be carried out as follows:
1. Switch the drive motor off.
2. Drain the oil out and clean the bearing housing with a suitable cleaning liquid. Flushing the bearing
housing with clean lightweight oil is possible (e.g. ATF).
3. Locate the constant level oiler assembly and identify its three main components: the oil tank, the oil
tank cap and the oil tank reservoir.
Figure 6.1a. Constant level oiler (assembly).
Figure 6.1b. Oil tank.
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Split Case, Centrifugal Pump
Figure 6.1c. Oil tank cap (with socket screws).
Figure 6.1d. Oil tank reservoir.
4. Untighten the socket screws of the oil tank cap.
5. Remove the oil tank cap along the oil tank reservoir.
6. Unscrew and remove the oil tank reservoir from the oil tank cap.
7. Pour oil into the oil tank as necessary until the oil level reaches the label marked on the oil tank.
8. Place the oil tank cap on the oil tank and tighten the socket screws.
9. Fill the oil tank reservoir up to ¾ of its capacity.
10. Place the oil tank reservoir on the oil tank cap and fasten.
11. The oil tank reservoir of the constant level oiler will have an initial level of approximately two thirds
when it reaches a stable state.

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If it is suspected that the bearings have been exposed to dirt or moisture,
thoroughly clean the bearings and frame with a solvent and air-dry the parts
before adding lubricant. Disassembly, inspection, cleaning, and reassembly
procedures are provided in SECTION EIGHT - MAINTENANCE.
ZW
Split Case, Centrifugal Pump
6.3 OTHER LUBRICATION
For proper lubrication of driver bearings and shaft couplings, see manufacturer instructions.
6.3.1 Packing Box
Packing is continuously lubricated internally with pumped fluid. Proper tightening procedures are explained
in Section 7.2.1 – Packing Strips and Packing Gland Tightening Procedure With Flush Lines With Valves and
Section 7.2.2 – Packing Strips and Packing Gland Tightening Procedure With Flush Lines Without Valves or
Without Flush Lines.
6.3.2 Mechanical Seals
For proper lubrication of the mechanical seal, please refer to the provided seal plan drawing and the
mechanical seal manufacturer’s manual.
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Split Case, Centrifugal Pump
7. OPERATION

For electric motor drives connect power supply to conform with national and
local codes. Line voltage and wire capacity must match the rating stamped on the
motor nameplate.

Before starting the pump, check the required direction of rotation of the pump.
The proper direction is indicated by direction arrow on the pump casing. Separate
the coupling halves then start motor to see that it rotates in the direction
required by the pump. If shaft rotation is incorrect, consult driver manufacturer's
instructions in order to change rotation. The coupling halves now can be
reconnected and the pump primed for starting.
7.1 PRIMING
Install pet cock valve the on upper half casing.

CAUTION: Before starting the pump, the casing and suction line must be filled
with liquid.
The pump must not be run until it is completely filled with liquid, because of danger of injuring some of the
parts of the pump which depend upon liquid for lubrication. Casing wear rings will not seize when the
pump is filled with liquid but are very likely to do so when the pump is run dry.
7.1.1 Priming by Suction Pressure
When operating under a suction pressure, priming may be accomplished by bleeding all of the air out of the
pump by opening the petcock located at the top of the upper casing.
A pump operating under a suction lift may be primed by any of the following methods, as may be best
suited to the conditions. The discharge valve should be closed during priming operation.
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Split Case, Centrifugal Pump
7.1.2 Priming by Ejector or Exhauster
This method is used when steam, high pressure water, or compressed air is available.
1. Attach an air ejector to the highest point in the pump casing. This will remove the air from the pump
and suction line.
2. As soon as the ejector waste pipe throws water continuously, the pump may be started. After
starting, a steady stream of water from the waste pipe indicates the pump is primed. If this stream
of water is not obtained, the pump must be stopped at once and the process of priming repeated. A
foot valve is unnecessary when this kind of device is used.
3. Open the discharge valve slowly and close off the ejector.
7.1.3 Priming by foot valve
When it is not practical to prime by ejector or exhauster, the pump may be primed by the use of a foot
valve. The foot valve will prevent liquid running out through the suction inlet and the pump can be
completely filled with liquid from some outside source. Pet cocks on the top of the pump should be opened
during filling to allow the air to escape. A tight foot valve will keep the pump constantly primed so that the
pump may be used for automatic operation. However, the valve must be inspected frequently to make sure
it does not develop leaks and thus the pump could be started dry.
7.1.4 Priming by Vacuum Pump
When none of the above methods of priming is practical, the pump may be primed by the use of the
vacuum pump to exhaust the air from the pump casing and suction line. A wet vacuum pump is preferable,
as it will not be damaged if water enters it. When a dry vacuum pump is used, the installation must be such
as to prevent liquid being taken into the air pump. The vacuum pump manufacturer's instructions should
be followed.
7.2 STARTUP
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
Every time before the pump is started up the safety devices must be mounted
and fastened.

In order to avoid risks of injury or damage, all pump units must be equipped with
emergency-stop devices.
ZW
Split Case, Centrifugal Pump

For operation of electrical drives, control systems and their cable routes, the
safety instructions issued by their manufacturers must be observed.

When the pump is shipped with a cartridge mechanical seal type installed, the
setting devices on the seal collar might be engaged. In this case, it is necessary to
tighten the set screws, disengage these setting devices from the seal, and turn
them to allow the operation of the pump. To perform this procedure, please
follow the instruction manual from the seal manufacturer.
Figure 7.1. Seal setting devices.
Position of discharge valve on starting
A high or medium head centrifugal pump, when primed and operated at full speed with the discharge gate
valve closed will require much less energy than when it is operated at its rated head and flow with the gate
valve open. For this reason it is usually advantageous to have the discharge gate valve closed when the
pump is being started. The pump must not be throttled by the use of a valve in the suction line.

WARNING: Operating the pump with a closed discharge valve can result in
excessive heat build-up and should be limited to the shortest practical duration.
Operating the pump close to shut-off head usually places greater bending strains
on the shaft than at operating points near the best efficiency point.
The following list of important items should be checked before the pump is started after initial installation
or repair
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Split Case, Centrifugal Pump

Pump and driver bolted securely

Coupling properly aligned

Piping complete

Correct rotation

Pump shaft turns freely

Discharge valve closed

Suction valve (if used) open

Seal water valve (if used) open

Pump completely primed

Motor and pump properly lubricated
Only after these items have been checked should the pump be started.

WARNING: Exposed coupling and shafting between pump and driver must be
protected with coupling guard and/or shaft guard prior to pump start-up and
operation.
Priming accomplished and correct shaft rotation established, the pump is ready for continued operation.
Therefore, after all the above mentioned items have been considered, the startup procedure is as follows:
1. Verify that the discharge valve is closed. For high energy pumps, open the discharge valve to
approximately ¼ fully open.
2. Start driver.
3. Completely open the discharge valve IMMEDIATELY when the operating speed has been reached.

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DANGER: Do not allow discharge valve to remain closed for any length of time.
Pumped fluid temperature will rise excessively causing damage to pump.
ZW
Split Case, Centrifugal Pump
NOTE: Once the pump is operating, if your pump is equipped with packing strips as a sealing option, then
the packing strips and packing gland tightening procedure must be carried out.

To operate pumps without flush lines, the following conditions must be met:

A positive suction pressure (above ambient pressure) is required.

The differential pressure between suction and ambient pressures must be at
least 1 bar (14.5 psi).
If your pump is equipped with flush lines with valves, refer to Section 7.2.1 - Packing Strips and Packing
Gland Tightening Procedure With Flush Lines With Valves. Otherwise, refer to Section 7.2.2 - Packing Strips
and Packing Gland Tightening Procedure With Flush Lines Without Valves or Without Flush Lines.
7.2.1 Packing Strips and Packing Gland Tightening Procedure With Flush Lines With Valves
To properly place and tighten the packing strips and packing glands follow these steps:
1. Insert the first set of packing strips over the shaft from the coupling side. Install each packing strip
individually. Make sure the joints of each packing strip are separated 90 degrees from each other.
2. Insert the lantern ring over the shaft from the coupling side until it reaches the first set of packing
strips. Make sure the lantern ring is in contact with the flush line’s hole.
3. Insert the second set of packing strips over the shaft sleeve. Remember to install each packing strip
individually, separating the joints of each packing strip 90 degrees from each other.

The quantity of the packing strips on each set placed before and after the lantern
ring may vary in order to correctly place the lantern ring below the flush line’s
hole.
4. Assemble the two equal halves of the packing gland.
5. Insert two set screw bolts to secure both halves of the packing gland together. The head of both
bolts should be on opposite sides.
6. Insert the packing gland over the shaft from the coupling side until it reaches the pump’s case.
7. Manually place the washers and hex nuts over the studs to secure the packing gland to the pump’s
case.
8. Repeat steps 1 thru 7 to place the packing strips and packing gland on the pump’s non coupling side.
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Split Case, Centrifugal Pump
9. Before starting the pump, make sure that the packing strips are quite loose on both sides of the
pump and that the flush valves are completely open.
Figure 7.2. Flush line valve in its open position.
10. Start the pump up.
11. From the coupling side, observe the leakage rate thru the packing gland. The pump must be run for
20 minutes with steady leakage before any tightening is performed.
12. The status of the flush valve will depend on the following condition:
a. If the pump´s suction pressure is equal or larger than 15 psi (1 bar), then flush valve must be
completely closed.
Figure 7.3. Flush line valve in its closed position.
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Split Case, Centrifugal Pump
b. If the pump´s suction pressure is less than 15 psi (1 bar), then the flush valve must be
opened to a 50% of its capacity (45 degrees).
Figure 7.4. Flush line valve opened to a 50% capacity (45 degrees).
13. The pump must be run for 10 minutes with a steady leakage before any tightening is performed.
14. Depending on the pump´s suction pressure and the flush valve´s position, follow one of these sets of
instructions to tighten the packing gland:
a. If the pump´s suction pressure is equal or greater than 15 psi (1 bar) and the flush valve is
completely closed:
i.
Using a wrench, tighten the hex nuts that secure the packing gland to the case very
slowly (about 1/8 of a turn) in an alternating pattern.
ii.
Let the packing strips set for approximately 5 minutes after each tightening cycle is
performed. Observe the leakage rate.
iii.
Repeat steps i and ii until an acceptable leakage rate thru the packing gland is
reached (a minimum of 120 drops per minute is required).
b. If the pump´s suction pressure is less than 15 psi (1 bar) and the flush valve is opened to a
50% of its capacity (45 degrees):
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i.
Using a wrench, tighten the hex nuts that secure the packing gland to the case very
slowly (about 1/8 of a turn) in an alternating pattern.
ii.
Let the packing strips set for approximately 5 minutes after each tightening cycle is
performed. Observe the leakage rate.
iii.
Repeat steps i and ii until an acceptable leakage rate thru the packing gland is
reached (a minimum of 120 drops per minute is required).
ZW
Split Case, Centrifugal Pump
iv.
If after 5 tightening cycles repeating steps i and ii the leakage is rate is still greater
than 120 drops per minute, then the flush line must be closed 9 degrees its capacity
and the pump must be left running for 5 minutes.
Figure 7.5. Flush line valve, first in its 50% capacity (45 degrees) position and then in its subsequent 9 degrees
possible positions.
v.
Repeat steps i thru iv as necessary until the acceptable leakage rate of 120 drops per
minute is reached.

WARNING: In no case should the leakage rate be allowed to be inferior to 120
drops per minute as this increases the risk of burning the packing strips.
15. Once finished, repeat steps 9 thru 14 on the non-coupling side.
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
Since packing strips are lubricated by the pumped fluid, it is very important that
they are not tightened to the point that no leakage occurs, since this will cause
the packing strips to burn and severe damage and scoring to the shaft and shaft
sleeve may occur.

After the packing strips and packing gland tightening procedure has been
finished, manual rotation of the shaft (or rotor) must be possible.
ZW
Split Case, Centrifugal Pump

Once the packing strips and packing gland are correctly tightened, the flush line
valves must not be closed any further.
7.2.2 Packing Strips and Packing Gland Tightening Procedure With Flush Lines Without Valves or Without
Flush Lines
To properly place and tighten the packing strips and packing glands follow these steps:
1.
Insert the first set of packing strips over the shaft from the coupling side. Install each packing
strip individually. Make sure the joints of each packing strip are separated 90 degrees from each
other.
2.
Insert the lantern ring over the shaft from the coupling side until it reaches the first set of
packing strips. Make sure the lantern ring is in contact with the flush line’s hole.
3.
Insert the second set of packing strips over the shaft sleeve. Remember to install each packing
strip individually, separating the joints of each packing strip 90 degrees from each other.

56
The quantity of the packing strips on each set placed before and after the lantern
ring may vary in order to correctly place the lantern ring below the flush line’s
hole.
4.
Assemble the two equal halves of the packing gland.
5.
Insert two set screw bolts to secure both halves of the packing gland together. The head of both
bolts should be on opposite sides.
6.
Insert the packing gland over the shaft from the coupling side until it reaches the pump’s case.
7.
Manually place the washers and hex nuts over the studs to secure the packing gland to the
pump’s case.
8.
Repeat steps 1 thru 7 to place the packing strips and packing gland on the pump’s non coupling
side.
9.
Before starting the pump, make sure that the packing strips are quite loose on both sides of the
pump.
10.
Start the pump up.
11.
From the coupling side, observe the leakage rate thru the packing gland. The pump must be run
for 20 minutes with steady leakage before any tightening is performed.
12.
Using a wrench, tighten the hex nuts that secure the packing gland to the case very slowly
(about 1/8 of a turn) in an alternating pattern.
V9.100319
ZW
Split Case, Centrifugal Pump
13.
Let the packing strips set for approximately 5 minutes after each tightening cycle is performed.
Observe the leakage rate and the differential pressure between the suction pressure and the
flush line.
14.
Repeat steps 12 and 13 until an acceptable leakage rate thru the packing gland is reached (a
minimum of 120 drops per minute is required).
15.
Once finished, repeat steps 9 thru 14 on the non-coupling side.

Since packing strips are lubricated by the pumped fluid, it is very important that
they are not tightened to the point that no leakage occurs, since this will cause
the packing strips to burn and severe damage and scoring to the shaft and shaft
sleeve may occur.

After the packing strips and packing gland tightening procedure has been
finished, manual rotation of the shaft (or rotor) must be possible.
7.3 OPERATING CHECK
During the initial operating hours, the pump should be monitored constantly. It is thus possible to detect
irregularities immediately and to take appropriate measures for their elimination (See SECTION ELEVEN TROUBLESHOOTING CHART).
As soon as the pump and driver have reached the normal operating temperature, the unit should be shut
down for final coupling alignment.
To monitor flow, pressure, temperature, and lubrication, regular visual inspection and monitoring is
advisable and/or necessary during operation.
Ruhrpumpen recommends checking the pump constantly at regular intervals in order to detect problems
early, in case they arise.
The operational check routine must include minimum the following points:


57
Beware of freely rotating parts, when the pump is in operation there is a high risk
of injury.
Check at regular intervals that the safety equipment is sound and is arranged and fastened
according to the regulations, and energized where applicable.
V9.100319
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Split Case, Centrifugal Pump

Check the security of all bolting, piping, and wiring.

Check all gauges, valves and instruments for proper working order.

Check all equipment for proper lubrication and correct rotation.

Check the oil level and validate that the correct oil grade is used (in oil lubricated pumps).

Check that the pumping unit is running quietly and without vibrating.

Unusual or too loud noises point towards a possible fault.

Monitor the power consumption of the drive motor. Low or excessive power consumption indicates
a possible fault.

Check the sealing system:
a.
Refer to the seal manufacturer for his estimate of maximum acceptable leakage rate, as this
will depend on application, design, location and the sealed liquid characteristics.
b.
If leakage is excessive, switch the pump off as quickly as possible, isolate the pump by closing
the discharge and suction valves or using some other approved method designated as safe
for your system, and check the rotating seal ring and the stationary seal ring.

If the sealing system of the mechanical seal fails, the pump must be taken out of
operation immediately.

The pump may only be operated under the minimum operating range for short
periods. The minimum pump flow is given in the characteristic line.
7.4 DOWELING (OPTIONAL)
When the pump has reached operating temperature and pressure,
1. Stop pump.
2. Check alignment and reset the equipment, if required.
3. Dowel the pump.
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Split Case, Centrifugal Pump
4. Dowel the driver.
5. Start the pump as defined in SECTION 7.2-STARTUP.
7.5 STOPPING
1. Throttle pump discharge to minimum flow.

WARNING: Do not close suction valve, this will cause the pump to run dry.
2. Turn the power off to the driver.
3. Close the pump discharge valve.
4. Observe the run-down of the pump until full stop.

If the rotor is jerky or suddenly stops, there is a danger that the rotor has become
blocked. The pump must be opened and all running clearances checked.
5. Close the suction valve when the pump shaft stops rotating as the pump must be isolated before
examination and made safe.

Do not close the suction valve until the pump has come to a full stop, as it may
cause the pump to run dry.
6. Ensure the drive motor cannot be unintentionally turned on.
7. Ensure the shut-off devices in the suction and pressure pipes cannot be unintentionally opened.
8. Drain the pump and the auxiliary piping.

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If the outside temperature is below 32 °F (0 °C), all cooling chambers must be
emptied, and all seal system cooling coils must be drained.
ZW
Split Case, Centrifugal Pump
7.6 SHORT-TERM SHUTDOWN
If the pump has switched off correctly and has not suddenly come to a halt, it may be re-started without
the need to take any special measures.
If the pump comes to a sudden halt, or if the pump was switched off because of a possible danger, it must
be checked for damage.
7.7 LONG-TERM SHUTDOWN
1. Follow the stopping procedure described in SECTION 7.5 - STOPPING.
2. Disconnect the vent filter and seal openings on the bearing frame to lessen the exchange of air.
3. While the unit is idle:
a. If the plant is in an operational state, warm up and start the unit at monthly intervals (see
SECTION 7.2 - STARTUP for details).
b. If the plant is not in an operational state, turn the unit over by hand a couple of times at
monthly intervals, ensuring the shaft is not returned to the same position, to allow the
bearings to rest in a different position every time.
4. If there is danger of freezing, drain the pump, drain the oil from the pump bearings and all the
auxiliary piping.
Change the oil before recommencing operation, ensuring the correct grade and the correct volume has
been filled in the bearing frame (see SECTION SIX - LUBRICATION for details).
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Split Case, Centrifugal Pump
8. MAINTENANCE
To perform the maintenance of the ZW pump, no special (custom made) tools are needed.
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
Before initiating maintenance procedures disconnect all power sources to the
equipment and discharge any parts which may retain an electric charge. Use
proper locks to avoid accidental start-up of the pump system. Failure to comply
may result in severe personal injury.

When performing the maintenance of the pump, use the safety equipment
appropriate for the pumped fluid, materials, and location of the equipment, such
as gloves, safety glasses, harnesses and other equipment regarded as mandatory
by the plant’s safety instructions.

IMPORTANT: For any component/accessory that has not been manufactured by
Ruhrpumpen and is part of the pump’s equipment, a complete reading of said
component/accessory manufacturer’s manual must be carried out for further
information on proper maintenance procedures and relevant safety warnings.

Correct and orderly installation/assembly is necessary for trouble-free operation
of the unit. Ruhrpumpen does not assume any liability for damage resulting from
inadequate installation/assembly. The chosen location for installation must offer
enough space for maintenance activities. Ruhrpumpen recommends consulting
also API Recommended Practices 686 to ensure proper installation in your facility.
ZW
Split Case, Centrifugal Pump

IMPORTANT: Vertical ZW pumps are equipped with NPT holes on both sides of
the suction chamber which are designed for vent / drain purposes when the
pump is in its vertical position.
Figure 8.1 Vent / drain NPT holes.
8.1 DISASSEMBLY
8.1.1 Disassembly Horizontal Pump
1. Stop the pump. See SECTION 7.5 - STOPPING.
2. Drain all possible fluids from the pump case and bearing houses.
3. Disconnect any auxiliary piping and wiring that could interfere with disassembly.
4. Disconnect the driver-to-pump coupling and remove coupling spacer.
5. When disassembling the pump, match mark, tag or otherwise identify all parts, and provide
separate containers for small parts. Refer to the sectional drawing of the pump included in SECTION
TEN - PARTS INFORMATION for the correct identification of the parts.
6. Disconnect seal water lines (if used). Remove oiler piping on oil lube pumps.
7. Remove the hexagonal head screw bolts that join the upper and lower casings.
8. Position two lifting lugs in the bosses on the upper casing.
9. Remove the hexagonal head screw bolts that join the stuffing boxes with the upper casing on each
pump side.
10. Loosen a little, but do not remove yet, the hexagonal head screw bolts on each pump side that join
the stuffing boxes with the lower casing.
11. With help of the jackscrews, separate the upper and lower casings.
12. Lift off the upper casing from the lifting lugs and place it on a separate flat and clean surface.
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Split Case, Centrifugal Pump
13. To remove the bearing housing and bearing cover from the rotor assembly:
a. Remove the four hexagonal head screw bolts that join the bearing housing to the stuffing
box.
b. Remove the four hexagonal head screw bolts that join the bearing cover and the bearing
housing.
c. Separate the bearing housing and the bearing cover from the rotating element and pull them
out.
d. Repeat this procedure on the other side.
14. For pumps with the packing option only:
a. Remove the washers and the nuts of the studs that hold the packing gland, and then remove
the packing gland.
b. Remove the packing rings and the lantern ring.
15. These steps apply only for the non-driven end of the pump:
a. Open the tab of the lockwasher bent on the locknut.
b. Unscrew and remove the locknut, and then remove the lockwasher.
c. Remove the thrust (axial) bearing from the shaft, with a bearing extractor/puller.
16. This step applies only for the driven end of the pump:
a. Remove the radial bearing from the shaft, with a bearing extractor/puller.
17. Remove the O-ring from the bearing cover.
18. Remove the lip seal (or labyrinth seal) from the bearing housing of the non-driven side and both lip
seals (or labyrinth seals) from the bearing covers.
19. Remove the diffuser on each side from the shaft.
20. These steps apply only for pumps with mechanical seal, and are to be performed on each side of the
rotor assembly:
a. Carefully unscrew the four screw bolts that join the seal gland to the stuffing box. Loosen
them evenly, gradually and crosswise, in order to avoid damages to the seal face. Finally,
remove the seal gland.
b. Remove the static face of the mechanical seal from the seal gland.
c. Remove the rotating parts of the mechanical seal from the shaft.
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Split Case, Centrifugal Pump
21. Remove the hexagonal head screw bolts on each pump side that join the stuffing boxes with the
lower casing.
22. Remove the stuffing boxes from the shaft and the O-ring from each stuffing box.
23. Lift out the rotor assembly and place it on an adequate structure to support it and allow its safe
disassembly.
24. Remove the O-band from the lower casing.
25. Remove the casing wear ring from the impeller.
26. Unthread both shaft sleeves, and remove their O-rings.
27. Pull the shaft from the impeller and remove the impeller key.
8.1.2 Disassembly Vertical Pump
1. Stop the pump. See SECTION 7.5 - STOPPING.
2. Drain all possible fluids from the pump case and bearing houses.
3. Disconnect any auxiliary piping and wiring that could interfere with disassembly.
4. When disassembling the pump, match mark, tag or otherwise identify all parts, and provide
separate containers for small parts. Refer to the sectional drawing of the pump included in SECTION
TEN - PARTS INFORMATION for the correct identification of the parts.
5. Remove the coupling guard.
6. Loosen the screws that secure the motor coupling hub to the shaft.
7. Slide the motor coupling hub up to separate the coupling between the motor and the pump.
8. Tighten the corresponding screws to secure the motor coupling hub to the shaft in its new
(temporary) position.
9. Secure or remove the motor shaft key.
10. Remove the coupling intermediate element (spacer).
11. With the help of a crane and slings, secure the motor so that it will not tilt during the removal of the
screws that fix it to the motor support.
12. Untighten and remove the corresponding screws that fix the motor to the vertical frame.
13. Lift and remove the motor from the vertical frame and place it on a flat surface. Make sure that the
motor is in a stable position and that the shaft end does not touch any bounding surfaces.
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Split Case, Centrifugal Pump

Make sure that the electric motor shaft is protected when the motor is removed
from the vertical frame and/or when it is being installed on the support. During
the removal of the coupling hub from the motor shaft, it is recommended that
the protection for the motor shaft end (guard), which is supplied with the motor,
is installed.
14. Using a crane and slings, lift the vertical frame using the front lifting lugs located at the motor stool,
keeping the back side of the vertical frame as a fulcrum.
15. Using a lift truck, lift the front side of the vertical frame, making the whole vertical frame rotate in
the fulcrum created in the previous step.
16. Maneuver the crane and the lift truck until the vertical frame is in a horizontal position. The lift truck
pushes the vertical frame´s front part up while the crane supports the weight of the back of the
vertical frame.

Place pieces of wood or a soft material on a flat surface so that the vertical frame
can be laid down
17. Using a crane and slings, secure the motor stool.
18. Untighten and remove the corresponding bolts that fix the motor stool to the back column of the
vertical frame.
19. Untighten and remove the corresponding bolts that fix the front support columns with the upper
part of the vertical frame.
20. Using the crane and slings already attached to the motor stool, remove the motor stool and place it
on a horizontal, flat surface.
21. Untighten and remove the corresponding bolts that fix the front support columns to the lower part
of the vertical frame.
22. Using a crane and slings, secure the front support columns.
23. Untighten and remove the corresponding nuts that fix the front support columns to the pump.
24. Using the crane and slings already attached to the front support columns, remove the front support
columns and place them in a horizontal, flat surface.
25. Untighten and remove the corresponding bolts that fix the pump feet to the back columns.
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26. Attach slings to the pump, as shown in the bare shaft pump figure in SECTION 3.3 – TRANSPORT and
using a crane, lift the pump and place it on a horizontal, flat surface.
27. Remove the lubrication tubing on the non-coupling side of the pump.
28. Remove the corresponding lubrication tubing connectors on the non-coupling side of the pump.
29. Remove the lubrication tubing on the coupling side of the pump.
30. Remove the corresponding lubrication tubing connectors on the coupling side of the pump.
31. Untighten and remove the hex bolts that secure the non-coupling side stuffing box to the upper and
lower casing, leaving just two hex bolts to keep the non-coupling side stuffing box secured to the
lower casing.
32. Untighten and remove the hex bolts that secure the coupling side stuffing box to the upper and
lower casing, leaving just two hex bolts to keep the coupling side stuffing box secured to the lower
casing.
33. Untighten and remove the hex bolts that secure the upper casing to the lower casing.
34. Using a crane, remove the upper casing and place it on a flat surface.
35. Untighten and remove the corresponding hex bolts that secure the non-coupling side (axial) bearing
carrier to the non-coupling side stuffing box.
36. Remove the non-coupling side bearing carrier from the non-coupling side stuffing box.
37. Remove the non-coupling side bearing bushing from inside the non-coupling side bearing carrier.
38. Untighten and remove the remaining hex bolts that secure the non-coupling side stuffing box to the
lower casing.
39. Remove the non-coupling side stuffing box.
40. Untighten and remove the corresponding hex bolts that secure the coupling side bearing cover to
the coupling side bearing housing.
41. Untighten and remove the corresponding hex bolts that secure the coupling side bearing housing to
the coupling side stuffing box.
42. Remove the coupling side bearing housing.
43. Remove the corresponding lip seal from the coupling side bearing housing.
44. Unbend the tab that locks the bearing lockwasher to the bearing locknut.
45. Remove the bearing locknut.
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46. Remove the bearing lockwasher.
47. Remove the coupling side bearing.
48. Remove the coupling side bearing cover.
49. Remove the corresponding lip seal from the coupling side bearing cover.
50. Remove the deflector.
51. Depending if your pump is equipped with mechanical seal o packing seal, follow one of these two
options:
a. Mechanical seal:
i. Untighten and remove the corresponding bolts that secure the mechanical seal to
the coupling side stuffing box.
ii. Remove the mechanical seal.
b. Packing Seal:
i. Untighten and remove the hex nuts that secure the packing gland to the coupling
side stuffing box.
ii. Remove the corresponding washers from the studs that join the packing gland to the
coupling side stuffing box.
iii. Remove the corresponding studs that join the packing gland to the coupling side
stuffing box.
iv. Remove the packing gland.
v. Remove the corresponding hex nuts that secure both halves of the packing gland
together.
vi. Remove the corresponding hex bolts that hold the two halves of the packing gland
together.
vii. Separate both halves of the packing gland.
viii. Remove the second set of packing strips.
ix. Remove the lantern ring.
x. Remove the first set of packing strips.
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52. Untighten and remove the remaining hex bolts that secure the coupling side stuffing box to the
lower casing.
53. Remove the coupling side stuffing box.
54. Remove the shaft assembly from the lower casing.
55. Remove the corresponding O-band from the grooves of the lower casing.
56. Remove the corresponding pins from the casing wear rings (if applicable).
57. Remove the non-coupling side sleeve from the shaft.
58. Remove the corresponding O-ring from the non-coupling side sleeve.
59. Remove the coupling side sleeve from the shaft.
60. Remove the corresponding O-ring from the coupling side sleeve.
61. Remove the impeller from the shaft.
62. Remove the case wear rings (if applicable).
63. Remove the impeller wear rings (if applicable).
64. Remove the impeller key from the shaft.
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8.2 INSPECTION AND CLEANING
1. Thoroughly clean all parts with kerosene or equivalent and dry all parts with compressed air or a
clean, lint-free cloth.
2. Inspect all components for corrosion, erosion, pitting, and scoring. If required, replace with
Ruhrpumpen O.E.M. genuine replacement parts.
a. Visual check all individual parts for any damage.
b. Check the casing for wear.
c. Check the impeller for wear.
d. Check the radial clearance for wear.
e. Check the antifriction bearings.
f. Check all auxiliary piping.
g. Check for transmission elements of the coupling.
8.2.1 Casing Wear Ring and Impeller Wear Ring Inspection and Replacement
Casing and impeller wear rings should be replaced when they are badly worn and/or when the pump’s
performance does not meet the system’s requirements.
Whenever it is necessary to replace either ring due to wear, both rings must be replaced.
8.2.2 Vertical Pump Mechanical Seal Maintenance
1. Stop the pump. Refer to SECTION 7.5 STOPPING.
2. Drain all possible fluids from the pump case and power frames.
3. Disconnect any auxiliary piping and wiring that could interfere with disassembly.
4. When disassembling the pump, match mark, tag or otherwise identify all parts, and provide
separate containers for small parts. Refer to the sectional drawing of the pump included in SECTION
TEN – PARTS INFORMATION.
5. Untighten and remove the necessary bolts and nuts that fix the motor plaque to the back and front
support columns.
6. Using a crane and slings, carefully lift the motor plaque and place it on a clean, flat surface.
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7. Place slings around the pump´s discharge and suction flanges.
8. Untighten and remove the corresponding nuts that fix the upper and lower cases to the front
support columns.
9. Untighten and remove the corresponding bolts that fix the two front support columns to the
inferior base.
10. Remove the two front support columns from the inferior base.
11. Untighten and remove the four necessary bolts that fix the pump´s feet to the back columns.
12. Carefully remove the pump from the base and place it in its horizontal position on a clean, flat
surface.
13. Remove the slings from the pump´s discharge and suction flanges.
14. Unscrew and remove the hexagonal head screw bolts that join the upper and lower casings.
15. Position two lifting lugs in the bosses on the upper casing.
16. Remove the hexagonal head screw bolts the join the stuffing boxes with the upper casing on each
side.
17. Loose a little, but do not remove yet, the hexagonal head screw bolts on each pump side that join
the stuffing boxes with the lower casing.
18. With the help of jackscrews, separate the upper and lower casings.
19. With the help of a crane and slings, lift off the upper casing from the lifting lugs and place it on a
separate flat and clean surface.
20. To remove the bearing housing and bearing cover from the rotor assembly:
a. Remove the four hexagonal head screw bolts that join the coupling side bearing housing to
the coupling side stuffing box.
b. Remove the four hexagonal head screw bolts that join the coupling side bearing cover and
the coupling side bearing housing.
c. Separate the coupling side bearing housing and the coupling side bearing cover from the
rotating element and pull them out.
d. Repeat this procedure on the non – coupling side bearing housing and the non – coupling
side bearing cover.
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21. These steps apply only for the non – coupling side of the pump:
a. Open the tab of the lockwasher bent on the locknut.
b. Unscrew and remove the locknut, and then remove the lockwasher.
c. With the help of a bearing extractor/puller, remove the axial bearing from the shaft.
22. This step applies only for the coupling side of the pump:
a. With the help of a bearing extractor/puller, remove the radial bearing from the shaft.
23. Remove the O-ring from the bearing cover.
24. Remove the lip seal (or labyrinth seal) from the bearing housing of the non – coupling side and both
lip seals (or labyrinth seals) from the bearing covers.
25. Remove the diffuser on each side from the shaft.
26. Follow the next steps to remove the mechanical seal (these steps apply to each side of the pump):
a. Carefully unscrew the four screw bolts that join the seal gland to the stuffing box. Loosen
them evenly, gradually and crosswise, in order to avoid damages to the seal face. Finally
remove the seal gland.
b. Remove the static face of the mechanical seal from the seal gland.
c. Remove the rotating parts of the mechanical seal from the shaft.
27. Either perform the maintenance needed or completely replace the mechanical seal.
28. To reinstall the mechanical seal and reassemble the pump, refer to SECTION EIGHT –
MAINTENANCE.
29. Place a sling over the suction flange and a second sling over the discharge flange.
30. With the help of a crane and the slings placed on the previous step, carefully lift the pump and tilt it
so that it can be positioned vertically in the back columns, aligning their corresponding bolt holes.
31. Place and tighten the four bolts needed to fix the pump’s feet to the back columns.
32. Place the two front support columns on the lower base.
33. Place and tighten the corresponding bolts to fix the front support columns to the lower base.
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34. Still using the crane and the slings for safety support, align the bolt holes of the upper and lower
pump cases to the bolt holes on the front support columns.
35. Place and tighten the corresponding bolts and nuts to fix the pump’s upper and lower cases to the
front support columns.
36. Remove the slings from both the suction and the discharge flanges.
37. Using a crane and slings, carefully lift the motor plate and place it on the back and front support
columns.
38. Place and tighten the bolts and nuts necessary to fix the motor plate to the back and front support
columns.
39. Reconnect all necessary piping and wiring.
40. The pump is now reassembled.
41. Refer to SECTION 7.2 STARTUP for instructions on starting up the pump.
8.3 REASSEMBLY
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
Observe the plant's safety precautions when lifting heavy components. Request
help when moving or positioning them.

Mounting of bearings should be carried out in a dry, dust-free area away from
metal working or other machines producing shavings and dust to avoid
contamination of bearings.

The bearings should remain in their original packaging. Once they are to be
assembled in the shaft, they must be removed from their packaging, and the
preservative in the outside diameter and the bore must be wiped out.

Bearings should
contamination.

During assembly, all threads must be protected with an anti-seize agent.
be
demagnetized
before
mounting
them,
to
avoid
ZW
Split Case, Centrifugal Pump
8.3.1 ZW Mechanical Seal – Grease Lubrication Horizontal Reassembly
Please follow the steps detailed on this section to reassemble the ZW Mechanical Seal – Grease Lubrication
Horizontal pump. To reassemble the ZW Packing Seal – Grease Lubrication Horizontal pump refer to
Section 8.3.2 - ZW Packing Seal – Grease Lubrication Horizontal Reassembly.
1. Position the key in the shaft’s corresponding keyway.
Figure 8.2. Positioning the key in the shaft’s corresponding keyway.
2. Insert the shaft, starting from the coupling side, inside the impeller. The slot for the impeller key
must match. This should be done vertically.
Figure 8.3. Inserting the shaft inside the impeller.
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
The use of a working table with a hole in it and a crane are suggested.

Lubricate with grease or oil the inner diameter of the impeller and the outer
diameter of the shaft.
ZW
Split Case, Centrifugal Pump
3. Place the corresponding O-ring in the sleeve.
Figure 8.4. Placing the corresponding O-ring in the sleeve.
4. Insert the sleeve into the shaft until it reaches the impeller. It is inserted from the coupling side. Use
a hook wrench to tighten the sleeve to the shaft.
Figure 8.5. Inserting the sleeve into the shaft until it reaches the impeller.
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
Depending of the rotation of the pump, the threads for the sleeves on the shaft
could be RH (Right Hand) or LH (Left Hand). If one side is RH then the other must
be LH, the threads will never be the same for both sides.

Lubricate with grease or oil the inner diameter of the sleeve and the outer
diameter of the shaft.
ZW
Split Case, Centrifugal Pump
5. Place the corresponding O-ring in the other sleeve.
Figure 8.6. Placing the corresponding O-ring in the other sleeve.
6. Insert the sleeve into the shaft from the non-coupling side until it reaches the impeller. Use a hook
wrench to tighten the sleeve to the shaft.
Figure 8.7. Inserting the non-coupling side sleeve into the shaft.

Lubricate with grease or oil the inner diameter of the sleeve and the outer
diameter of the shaft.
7. Place two pins in the casing wear ring holes.
Figure 8.8. Placing two pins in the casing wear ring holes.
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8. Insert the casing wear ring into the impeller from the coupling side. The pins must be vertically
oriented.
Figure 8.9. Inserting the casing wear ring into the impeller from the coupling side.

Lubricate with grease or oil the inner diameter of the casing wear ring and the
outer diameter of the impeller.
9. Place two pins in the remaining casing wear ring.
Figure 8.10. Placing two pins in the remaining casing wear ring.
10. Insert the remaining casing wear ring into the impeller from the non-coupling side. The pins must be
vertically oriented.
Figure 8.11. Inserting the remaining casing wear ring into the impeller from the non-coupling side.
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
Lubricate with grease or oil the inner diameter of the casing wear ring and the
outer diameter of the impeller.
11. Place the corresponding O-band into the grooves of the lower casing.
Figure 8.12. Placing the corresponding O-band into the grooves of the lower casing.

Do not cut the excess of O-band when placing on the lower casing. It is of
paramount importance to ensure the correct sealing of the pump.

Apply silicon when placing the O-band in the lower casing. This to ensure that the
O-band remains in place during the assembly.
12. Place the shaft assembly into the lower casing. The lower pins on the wear rings should fit in the
lower casing holes.
Figure 8.13. Placing the shaft assembly into the lower casing.
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13. Place the corresponding O-ring in the stuffing box.
Figure 8.14. Placing the corresponding O-ring in the stuffing box.
14. Fasten the corresponding plugs into the stuffing box. On the mechanical seal option both plugs are
assembled and on the packing seal only one plug is used, usually the one that is in the lower
position.
Figure 8.15. Fastening the corresponding plugs into the stuffing box.
15. Introduce the stuffing box into the shaft from the coupling side. Arrange the stuffing box with the
lower casing so the screwing holes match.
Figure 8.16. Introducing the stuffing box into the shaft from the coupling side.
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16. Place and fasten (‘snug’) the corresponding screws of the stuffing box to the lower casing, but do
not tighten them completely. This will prevent future interference when placing the upper casing.
Make sure that the splitter is in the right place and direction, which is on the opposite direction of
the suction flange, and oriented 30° from the vertical axis.
30°
SUCTION
DISCHARGE
Figure 8.17. Fastening the corresponding screws to the stuffing box.
17. Place the corresponding O-ring in the remaining stuffing box.
Figure 8.18. Placing the corresponding O-ring in the remaining stuffing box.
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18. Fasten the corresponding plugs into the remaining stuffing box. On the mechanical seal option both
plugs are assembled and on the packing seal only one plug is used, usually the one that is in the
lower position.
Figure 8.19. Fastening the corresponding plugs into the remaining stuffing box.
19. Introduce the remaining stuffing box into the non-coupling side of the shaft. Arrange the stuffing
box with the lower casing so the screwing holes match.
Figure 8.20. Introducing the remaining stuffing box into the non-coupling side of the shaft.
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20. Place and fasten (‘snug’) the corresponding screws of the stuffing box to the lower casing, but do
not tighten them completely. This will prevent future interference when placing the upper casing.
Make sure that the splitter is in the right place and direction, which is on the opposite direction of
the suction flange, and oriented 30° from the vertical axis.
30°
DISCHARGE
SUCTION
Figure 8.21. Fastening the corresponding screws to the stuffing box.
In case your pump uses packing strips as seal, either grease or oil lubricated, please refer to
Section 8.3.2 - ZW Packing Seal – Grease Lubrication Horizontal Reassembly, Step 21 for the correct
reassembly procedure for steps 21 to 25.
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21. Introduce the rotating part of the mechanical seal into the stuffing box chamber from the coupling
side of the shaft.
Figure 8.22. Introducing the rotating part of the mechanical seal into the stuffing box chamber.
22. Place the static part of the mechanical seal inside the seal gland.
Figure 8.23. Placing the static part of the mechanical seal inside the seal gland.

Do not touch the mechanical seal friction faces; this may cause the malfunction of
the mechanical seal.
23. Insert the corresponding O-ring into the seal gland.
Figure 8.24. Inserting the corresponding O-ring into the seal gland.
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24. Place the seal gland in the stuffing box, the piping connection must be facing upwards.
Figure 8.25. Placing the seal gland in the stuffing box.
25. Fasten the corresponding screws to the seal gland.
Figure 8.26. Fastening the corresponding screws to the seal gland.

The fastening of the screws must be done cross wise.
26. Introduce the diffuser into the shaft from the coupling side.
Figure 8.27. Introducing the diffuser into the shaft from the coupling side.
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27. Insert the corresponding lip seal into the outer side of the bearing cover.
Figure 8.28. Inserting the corresponding lip seal into the outer side of the bearing cover.
28. Fasten the corresponding plug into the outer side of the bearing cover.
Figure 8.29. Fastening the corresponding plug into the outer side of the bearing cover.
29. Place the corresponding O-ring into the inner side of the bearing cover.
Figure 8.30.Placing the corresponding O-ring into the inner side of the bearing cover.
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30. Introduce the bearing cover into the coupling side of the shaft. The inner part of the bearing cover
should be facing outwards the pump.
Figure 8.31. Introducing the bearing cover into the coupling side of the shaft.
31. Insert the coupling side (radial) bearing into its corresponding position in the shaft from the
coupling side. Lubrication and heating required.
Figure 8.32. Inserting the coupling side (radial) bearing into its corresponding position in the shaft from the coupling
side.
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
The bearing must be heated to 100 °C / 212 °F. The bearing should be passed 3
times over the heater for demagnetization. This should be done for the proper
installation and function of the bearing.

Lubricate with grease or oil the inner diameter of the bearing and the outer
diameter of the shaft.
ZW
Split Case, Centrifugal Pump
32. Place the corresponding lip seal into the pump´s coupling side bearing housing.
Figure 8.33. Placing the corresponding lip seal into the pump´s coupling side bearing housing.
In case your pump has a mechanical seal and is lubricated by oil, please refer to Section 8.3.3 - ZW
Mechanical Seal – Oil Lubrication Horizontal Reassembly, Step 33 for the correct reassembly procedure for
steps 33 to 36.
In case your pump has packing seal and is lubricated by oil, please refer to Section 8.3.4 - ZW Packing Seal –
Oil Lubrication Horizontal Reassembly, Step 33 for the correct reassembly procedure for steps 33 to 36.
33. Fasten the corresponding plug into the outer side of the coupling side bearing housing.
Figure 8.34. Fastening the corresponding plug into the outer side of the coupling side bearing housing.
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34. Introduce the coupling side bearing housing into the shaft from the coupling side and arrange it
with the stuffing box so the screwing holes match.
Figure 8.35. Introducing the coupling side bearing housing into the shaft.
35. Fasten the corresponding screws into the coupling side bearing housing.
Figure 8.36. Fastening the corresponding screws into the coupling side bearing housing.

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The fastening of the screws must be done cross wise.
ZW
Split Case, Centrifugal Pump
36. Place and tighten the corresponding screws into the coupling side bearing cover. The bearing cover
plug must be downwards when placing in the bearing housing.
Figure 8.37. Placing and tightening the corresponding screws into the coupling side bearing cover.

The tightening of the screws must be done cross wise.
In case your pump has packing seal, either grease or oil lubricated, please refer Section 8.3.2 - ZW
Packing Seal – Grease Lubrication Horizontal Reassembly, Step 37, for the correct reassembly procedure
for steps 37 to 41.
37. Introduce the rotating part of the mechanical seal into the stuffing box chamber from the noncoupling side of the shaft.
Figure 8.38. Introducing the rotating part of the mechanical seal into the stuffing box chamber from the coupling
side.
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38. Place the static part of the mechanical into the seal gland.
Figure 8.39. Placing the static part of the mechanical into the seal gland.
39. Insert the corresponding O-ring into the seal gland.
Figure 8.40. Inserting the corresponding O-ring into the seal gland.
40. Insert the non-coupling side seal gland over the shaft until it reaches the stuffing box, the piping
connection must be facing upwards.
Figure 8.41. Inserting the non-coupling side seal gland over the shaft until it reaches the stuffing box.
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41. Fasten the corresponding screws to the non-coupling side seal gland.
Figure 8.42. Fastening the corresponding screws to the non-coupling side seal gland.

The fastening of the screws must be done cross wise.
42. Introduce the diffuser over the non-coupling side of shaft.
Figure 8.43. Introducing the diffuser over the non-coupling side of shaft.
43. Place the corresponding lip seal into the outer side of the non-coupling side bearing cover.
Figure 8.44. Placing the corresponding lip seal into the outer side of the non-coupling side bearing cover.
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44. Fasten the corresponding plug into the outer side of the non-coupling side bearing cover.
Figure 8.45. Fastening the corresponding plug into the outer side of the non-coupling side bearing cover.
45. Place the corresponding O-ring into the inner side of the non-coupling side bearing cover.
Figure 8.46. Placing the corresponding O-ring into the inner side of the non-coupling side bearing cover.
46. Insert the bearing cover over the non-coupling side of the shaft. The inner part should be facing
outwards the pump.
Figure 8.47. Inserting the bearing cover over the non-coupling side of the shaft.
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47. Insert the non-coupling side (axial) bearing into its corresponding position in the shaft from the noncoupling side. Lubrication and bearing heating required.
Figure 8.48. Inserting the non-coupling side (axial) bearing into its corresponding position in the shaft.

The bearing must be heated to 100 °C / 212 °F. The bearing should be passed 3
times over the heater for demagnetization. This should be done for proper
installation and function of the bearing.

Lubricate with grease or oil the inner diameter of the bearing and the outer
diameter of the shaft.
48. Once the bearing is cold, place and tighten the locknut in the shaft to make sure the bearing is in the
right position.
Figure 8.49. Placing and tightening the locknut in the shaft.

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The tightening of the locknut must be strong using a hook wrench and a hammer.
This to assure that the bearing contacts the step in the shaft.
ZW
Split Case, Centrifugal Pump
49. Loosen the locknut and remove it from the shaft.
Figure 8.50. Loosening the locknut and removing it from the shaft.
50. Insert the bearing washer over the shaft from the non-coupling side until it reaches the bearing. The
tabs of the washer must be facing outwards the pump.
Figure 8.51. Inserting the bearing washer over the shaft from the non-coupling side.
51. Reinsert the locknut over the shaft from the non-coupling side until it reaches the bearing washer.
Bend a tab of the washer towards one of the slots in the locknut.
Figure 8.52. Reinserting the locknut over the shaft from the non-coupling side until it reaches the bearing washer.
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
In search of a match between a tab of the washer and a slot of the locknut, the
locknut should always be turned to tighten, never to untighten.
52. Fasten the corresponding plug into the outer side of the non-coupling side bearing housing.
Figure 8.53. Fastening the corresponding plug into the outer side of the non-coupling side bearing housing.
In case your pump has a mechanical seal and is lubricated by oil, please refer to Section 8.3.3 - ZW
Mechanical Seal – Oil Lubrication Horizontal Reassembly, Step 53 for the correct reassembly procedure for
steps 53 to 56.
In case your pump has packing seal and is lubricated by oil, please refer to Section 8.3.4 - ZW Packing Seal –
Oil Lubrication Horizontal Reassembly, Step 53 for the correct reassembly procedure for steps 53 to 56.
53. Introduce the bearing housing into the shaft from the non-coupling side. Arrange it with the stuffing
box so the screwing holes match.
Figure 8.54. Introducing the bearing housing into the shaft from the non-coupling side.
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54. Fasten the corresponding screws into the non-coupling side bearing housing.
Figure 8.55. Fastening the corresponding screws into the non-coupling side bearing housing.

The fastening of the screws must be done cross wise.
55. Place the bearing cover and diffuser on the non-coupling side bearing housing, making sure that the
screw holes match. The bearing cover plug must be facing downwards when placing in the non-coupling
side bearing housing.
Figure 8.56. Placing the bearing cover and diffuser on the non-coupling side bearing housing.
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56. Place and tighten the corresponding screws into the bearing cover.
Figure 8.57. Placing and tightening the corresponding screws into the bearing cover.

The tightening of the screws must be done cross wise.
57. Fasten two eye bolts into the upper casing.
Figure 8.58. Fastening two eye bolts into the upper casing.
58. Place the upper casing over the lower casing, making sure that the screw holes match and the Oband maintains its position.
Figure 8.59. Placing the upper casing over the lower casing, making sure that the screw holes match.
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
Be sure to add RTV (Room Temperature Vulcanization) silicone gasket maker in
the junction between the case and the stuffing box O-ring.
59. Tighten the bolts corresponding to both casings. This should be done cross wise.
Figure 8.60.a Tightening of the bolts corresponding to both casings.
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Split Case, Centrifugal Pump
Figure 8.60.b. Cross wise tightening sequence.

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Full torque during the crosswise tightening sequence of the bolts to secure the
top case to the lower case must be achieved in 3 passes. The first pass must
tighten all the bolts with a 33% of the torque, the second pass must tighten all
the bolts with a 66% of the torque and the third and final pass will tighten all the
bolts with a 100% of the torque.
ZW
Split Case, Centrifugal Pump
60. Place two jacking bolts in the upper casing. Make sure not to tighten these bolts, as these are placed
and left in position for disassembly purposes.
Figure 8.61. Placing two jacking bolts in the upper casing.
61. Place the remaining screws corresponding to the stuffing box and the upper casing on the coupling
side, and tighten all screws (stuffing box to upper and lower casing) in a cross wise pattern and
applying torque.
Figure 8.62. Tightening the screws to the stuffing box and the upper casing on the coupling side.
62. Place the remaining screws corresponding to the stuffing box and the upper casing on the noncoupling side, and tighten all screws (stuffing box to upper and lower casing) in a cross wise pattern
and applying torque.
Figure 8.63. Tightening the screws to the stuffing box and the upper casing on the non-coupling side.
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63. At this point the pump has been completely assembled. Eyebolts must be removed.
Figure 8.64 Pump assembly completed.
64. Before starting the operation of the pump, manually rotate the shaft to make sure it moves without
any obstruction.
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The torque values by bolt size used during the reassembly are as follows:
BOLTING SIZE
M8
M10
M12
M16
M20
M24
M30
M48
TORQUE VALUES
N*m (lb*ft)
23 (17)
41 (30)
100 (74)
197 (145)
350 (258)
834 (615)
1 440 (1 062)
2 300 (1 700)
8.3.2 ZW Packing Seal – Grease Lubrication Horizontal Reassembly
The ZW Packing Seal – Grease Lubrication Horizontal Reassembly shares reassembly steps 1 thru 20, 26
thru 36, and 42 thru 64, with the ZW Mechanical Seal – Grease Lubrication Horizontal Reassembly. Please
follow the aforementioned steps from the ZW Mechanical Seal – Grease Lubrication Horizontal Reassembly
procedure found in Section 8.3.1 - Mechanical Seal – Grease Lubrication Horizontal Reassembly when
reassembling the pump.
Intermediate steps to reassemble the ZW Packing – Grease Lubrication Horizontal Reassembly, steps 21 to
25 for the driven (coupling) side are the following:
21. On the coupling side, place the piping and the packing gland studs in their place.
a) Insert the 45° plug for the lubrication plan. Make sure to put “Teflon” tape on the thread.
Figure 8.22.a Inserting the 45° plug for the lubrication plan.
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b) Insert the two corresponding studs into the case cover. They must be in opposite sides, at 180°
from each other.
Figure 8.22.b Inserting the two corresponding studs into the case cover.
22. Insert the packing components into the chamber on the stuffing box.
a) Insert the washer over the sleeve into the packing chamber.
Figure 8.23.a Inserting the washer over the sleeve into the packing chamber.
b) Insert two strips of packing in the packing chamber rolled around the sleeve.
Figure 8.23.b Inserting two strips of packing in the packing chamber rolled around the sleeve.
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c)
Assemble and insert the lantern ring over the shaft until it reaches the packing strips.
Figure 8.23.c Assembling and inserting the lantern ring into the shaft until it reaches the packing strips.
d)
Place two strips of packing inside the packing chamber. Make sure the packing strips are in
contact with the lantern ring.
Figure 8.23.d Placing two strips of packing inside the packing chamber.

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The joining faces of each strip must not be aligned, to ensure a proper assembly
and function. The joining faces must be staggered at 90°.
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Split Case, Centrifugal Pump
The packing strip cuts must be done as indicated below:
•
The cut of a packing strip for valves must always be made at 45°.
•
If the stuffing box section of a centrifugal pump is equal or less than ½ in, the packing strip cut
must be made at 45°.
•
If the stuffing box section of a centrifugal pump is greater than ½ in, the packing strip cut must
be made at 90°.
Figure 8.23.e Packing strip cut at 45°(left) and 90° (right).

First set of packing strips.
Usually consists of three
packings.
The number of packing strips before and after the lantern ring may vary in order
to place the lantern ring directly below the flush line’s hole. Usually the first set
consists of three packings while the second set usually consists of two packings.
Second set of packing strips.
Usually consists of two packings.
Lantern ring placed
directly below the flush
line´s hole.
Figure 8.23.f Packing strip set and lantern ring placement.
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23. Assemble and insert the packing gland over the shaft.
a)
Assemble the two equal halves of the packing gland.
Figure 8.24.a Assembling the two equal halves of the packing gland.
b)
Insert the corresponding screw bolts to fix the two halves of the packing gland together. The
head of both bolts should be in opposite sides.
Figure 8.24.b Inserting the corresponding screw bolts to fix both halves of the packing gland together.
c)
Once assembled, insert the packing gland over the shaft. Make sure that packing gland is
correctly aligned with the studs.
Figure 8.24.c Inserting the packing gland over the shaft.
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24. Place the washers in their corresponding positions on the packing gland studs.
Figure 8.25 Placing the washers in their corresponding positions on the packing gland studs.
25. Place and tighten the nuts in their corresponding positions on the packing gland studs.
Figure 8.26 Placing and tightening the nuts in their positions on the packing gland studs.
After finishing these steps, refer to the Section 8.3.1 - ZW Mechanical Seal – Grease Lubrication
Horizontal Reassembly, Step 26.
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Steps 37 to 41 for the non-coupling side for pumps with packing strips as seal are the following:
37. On the non-coupling side, place the piping and the packing gland studs in their place.
a) Insert the 45° plug for the lubrication plan. Make sure to put “Teflon” tape on the thread.
Figure 8.38.a. Inserting the 45° plug for the lubrication plan.
b) Insert the two corresponding studs into the case cover. They must be in opposite sides, at
180° from each other.
Figure 8.38.b. Inserting the two corresponding studs into the case cover.
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38. Insert the packing components inside the chamber on the stuffing box.
a) Insert the washer inside the packing chamber over the sleeve.
Figure 8.39.a. Inserting the washer inside the packing chamber over the sleeve.
b) Insert two strips of rolled up packing strips over the shaft sleeve, inside the packing
chamber.
Figure 8.39.b. Inserting two strips of rolled up packing strips over the shaft sleeve, inside the packing chamber.

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The joining faces of each strip must not be aligned, to ensure a proper assembly
and function.
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Split Case, Centrifugal Pump
c) Assemble and insert the lantern ring over the shaft until it reaches the packing strips.
Figure 8.39.c. Assembling and inserting the lantern ring over the shaft until it reaches the packing strips.
d)
Insert two strips of packing inside the packing chamber. Make sure the packing is in contact
with the lantern ring.
Figure 8.39.d. Inserting two strips of packing inside the packing chamber.

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The joining faces of each strip must not be aligned, to ensure a proper assembly
and function. The joining faces must be staggered at 90°.
ZW
Split Case, Centrifugal Pump
The packing strip cuts must be done as indicated below:
•
The cut of a packing strip for valves must always be made at 45°.
•
If the stuffing box section of a centrifugal pump is equal or less than ½ in, the packing strip cut
must be made at 45°.
•
If the stuffing box section of a centrifugal pump is greater than ½ in, the packing strip cut must
be made at 90°.
Figure 8.39.e Packing strip cut at 45°(left) and 90° (right).

First set of packing strips.
Usually consists of three
packings.
The number of packing strips before and after the lantern ring may vary in order
to place the lantern ring directly below the flush line’s hole. Usually the first set
consists of three packings while the second set usually consists of two packings.
Second set of packing strips.
Usually consists of two packings.
Lantern ring placed
directly below the flush
line´s hole.
Figure 8.39.f Packing strip set and lantern ring placement.
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39. Assemble and insert the packing gland over the shaft.
a)
Assemble the two equal parts of the packing gland.
Figure 8.40.a. Assembling the two equal parts of the packing gland.
b)
Insert the corresponding screw bolts into the packing gland. The head of both bolts should
be in opposite sides.
Figure 8.40.b. Inserting the corresponding screw bolts into the packing gland.
c)
Insert the packing gland over the shaft. Make sure that the studs and the packing gland
match with each other.
Figure 8.40.c. Inserting the packing gland over the shaft.
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40. Place the washers in their corresponding position on the packing gland studs.
Figure 8.41. Placing the washers in their corresponding position on the packing gland studs.
41. Place and tighten the nuts in their position on the corresponding studs on the packing gland.
Figure 8.42. Placing and tightening the nuts on their position on the corresponding studs on the packing gland.
After finishing these steps, refer to the Section 8.3.1 - ZW Mechanical Seal – Grease Lubrication
Horizontal Reassembly, Step 42.
The torque values by bolt size used during the reassembly are as follows:
BOLTING SIZE
M8
M10
M12
M16
M20
M24
M30
M48
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TORQUE VALUES
N*m (lb*ft)
23 (17)
41 (30)
100 (74)
197 (145)
350 (258)
834 (615)
1 440 (1 062)
2 300 (1 700)
ZW
Split Case, Centrifugal Pump
8.3.3 ZW Mechanical Seal – Oil Lubrication Horizontal Reassembly
The ZW Mechanical Seal – Oil Lubrication Horizontal Reassembly shares reassembly steps 1 thru 32, 37 thru
52, and 57 thru 64, with the ZW Mechanical Seal – Grease Lubrication Horizontal Reassembly. Please follow
the aforementioned steps from the reassembly procedure found in SECTION 8.3.1 - ZW Mechanical Seal –
Grease Lubrication Horizontal Reassembly when reassembling the pump.
Intermediate steps to reassemble the ZW Mechanical Seal – Oil Lubrication Horizontal Reassembly steps 33
to 36 for the driven side and step 53 to 56 for the non-driven side are the following:
a) Insert the bearing housing into the stuffing box.
b) Screw the bearing housing to the stuffing box with its corresponding bolts.
c) Screw the bearing housing to the bearing cover with its corresponding bolts.
d) From the outer side of the bearing cover, insert the lip seal.
e) Introduce the bearing cover into the shaft and place it in the bearing housing.
f) Tighten the bearing cover to the bearing housing. Tightening of the bolts must be done crosswise.
g) Insert the constant level oiler on one side of the bearing housing. Make sure the position is in the
side of the discharge of the pump.
After finishing these steps, refer to Section 8.3.1 - ZW Mechanical Seal – Grease Lubrication Horizontal
Reassembly, Step 37 to continue with the reassembly of the driven side.
After finishing these steps, refer to Section 8.3.1 - ZW Mechanical Seal – Grease Lubrication Horizontal
Reassembly, Step 57 to continue with the rest of the pump’s assembly.
8.3.4 ZW Packing Seal – Oil Lubrication Horizontal Reassembly
The ZW Packing – Oil Lubrication Horizontal Reassembly shares reassembly steps 1 thru 32, 37 thru 52, and
57 thru 64, with the ZW Packing – Grease Lubrication Horizontal Reassembly. Please follow the
aforementioned steps from the ZW Packing – Grease Lubrication Horizontal Reassembly procedure found
in Section 8.3.2 - ZW Packing Seal – Grease Lubrication Horizontal Reassembly when reassembling the ZW
Packing Seal – Oil Lubrication Horizontal Reassembly.
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Intermediate steps to reassemble the ZW Packing Seal – Oil Lubrication Horizontal Reassembly steps 33 to
36 for the driven side and step 53 to 56 for the non-driven side are the following:
a) Insert the bearing housing into the stuffing box.
b) Screw the bearing housing to the stuffing box with its corresponding bolts.
c) Screw the bearing housing to the bearing cover with its corresponding bolts.
d) From the outer side of the bearing cover, insert the lip seal.
e) Introduce the bearing cover into the shaft and place it in the bearing housing.
f) Tighten the bearing cover to the bearing housing. Tightening of the bolts must be done crosswise.
g) Insert the constant level oiler on one side of the bearing housing. Make sure the position is in the
side of the discharge of the pump.
After finishing these steps and continuing to step 37, refer to Section 8.3.2 - ZW Packing Seal – Grease
Lubrication Horizontal Reassembly, Step 37 to continue with reassembly of the driven side.
After finishing these steps and continuing to step 57, refer to Section 8.3.1 - ZW Mechanical Seal – Grease
Lubrication Horizontal Reassembly, Step 57 to continue with the rest of the pump´s assembly.
8.3.5 ZW Mechanical Seal – Grease Lubrication Vertical Reassembly
Follow the steps detailed on this section to reassemble the ZW Mechanical Seal – Grease Lubrication
Vertical Reassembly pump. To reassemble the ZW Packing Seal – Grease Lubrication Vertical Reassembly
pump refer to Section 8.3.6 - ZW Packing Seal – Grease Lubrication Vertical Reassembly.
1. Place the key in the shaft’s corresponding keyway.
Figure 8.65. Placing the key in the shaft’s corresponding keyway.
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
If your pump is equipped with casing and impeller wear rings, proceed with step
2. If your pump is equipped only with casing wear rings, skip to step 4.
2. Insert the impeller wear rings on the impeller.
Figure 8.66 Inserting the impeller wear rings on the impeller.
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3. Insert the case wear rings over the impeller wear rings.
Figure 8.67 Inserting the case wear rings over the impeller wear rings.

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After finishing these steps, and having already placed case and impeller wear
rings, proceed with step 5.
ZW
Split Case, Centrifugal Pump
4. Insert the case wear rings on the impeller.
Figure 8.68 Inserting the case wear rings on the impeller.
5. Insert the shaft, starting from the coupling side, inside the impeller. The slot for the impeller key
must match. This should be done vertically.
Figure 8.69. Inserting the shaft inside the impeller.
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
The use of a working table with a hole in it and a crane are suggested.

Lubricate with grease or oil the inner diameter of the impeller and the outer
diameter of the shaft.
6. Place the corresponding O-ring in the coupling side sleeve.
Figure 8.70. Placing the corresponding O-ring in the coupling side sleeve.
7. Insert the coupling side sleeve into the shaft until it reaches the impeller. It is inserted from the
coupling side. Use a hook wrench to tighten the sleeve to the shaft.
Figure 8.71. Inserting the coupling side sleeve into the shaft until it reaches the impeller.
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
Depending of the rotation of the pump, the threads for the sleeves on the shaft
could be RH (Right Hand) or LH (Left Hand). If one side is RH then the other must
be LH, the threads will never be the same for both sides.

Lubricate with grease or oil the inner diameter of the sleeve and the outer
diameter of the shaft.
ZW
Split Case, Centrifugal Pump
8. Place the corresponding O-ring in the non-coupling side sleeve.
Figure 8.72. Placing the corresponding O-ring in the non-coupling side sleeve.
9. Insert the non-coupling side sleeve into the shaft from the non-coupling side until it reaches the
impeller. Use a hook wrench to tighten the sleeve to the shaft.
Figure 8.73. Inserting the non-coupling side sleeve into the shaft.

Lubricate with grease or oil the inner diameter of the sleeve and the outer
diameter of the shaft.
10. Place the corresponding pins on the casing wear rings.
Figure 8.74. Placing the corresponding pins on the casing wear rings.
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11. Place the corresponding O-band into the grooves of the lower casing.
Figure 8.75. Placing the corresponding O-band into the grooves of the lower casing.

Do not cut the excess of O-band when placing on the lower casing. It is of
paramount importance to ensure the correct sealing of the pump.

Apply silicon when placing the O-band in the lower casing. This to ensure that the
O-band remains in place during the assembly.
12. Place the shaft assembly in the lower casing. The lower pins on the wear rings should fit in the lower
casing holes.
Figure 8.76. Placing the shaft assembly in the lower casing.
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13. Introduce the coupling side stuffing box into the shaft from the coupling side. Arrange the coupling
side stuffing box with the lower casing so the screwing holes match.
Figure 8.77. Introducing the coupling side stuffing box into the shaft from the coupling side.
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14. Place and fasten (‘snug’) the corresponding screws of the coupling side stuffing box to secure it to
the lower casing, but do not tighten them completely. This will prevent future interference when
placing the upper casing. Make sure that the splitter is in the right place and direction, which is on
the opposite direction of the suction flange, and oriented 30° from the vertical axis.
Figure 8.78. Tightening the corresponding screws to the coupling side stuffing box.
In case your pump uses packing strips as a seal, refer to Section 8.3.6 - ZW Packing Seal – Grease
Lubrication Vertical Reassembly for the correct reassembly procedure for the packing seal.
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15. To install the mechanical seal, follow these steps:
a.
Insert the mechanical seal over the shaft from the coupling side.
Figure 8.79a. Inserting the mechanical seal over the shaft from the coupling side.
b.
Place and tighten the corresponding bolts to secure the mechanical seal to the coupling
side stuffing box.
Figure 8.79b. Placing and tightening the corresponding bolts to secure the mechanical seal to the coupling side
stuffing box.

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The tightening of the bolts must be done cross wise.
ZW
Split Case, Centrifugal Pump
16. Insert the deflector over the shaft from the coupling side
Figure 8.80 Inserting the deflector over the shaft from the coupling side.
17. Insert the corresponding lip seal into the coupling side bearing cover.
Figure 8.81. Inserting the corresponding lip seal into the coupling side bearing cover.
18. Insert the coupling side bearing cover over the shaft from the coupling side.
Figure 8.82 Inserting the coupling side bearing cover over the shaft from the coupling side.
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19. Insert the coupling side bearing over the shaft from the coupling side.
Figure 8.83 Inserting the coupling side bearing over the shaft from the coupling side.
20. Insert the coupling side lockwasher over the shaft from the coupling side until it reaches the
coupling side bearing.
Figure 8.84 Inserting the coupling side lockwasher over the shaft from the coupling side.
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21. Insert the coupling side bearing locknut over the shaft from the coupling side until it reaches the
coupling side bearing lockwasher.
Figure 8.85 Inserting the coupling side bearing locknut over the shaft from the coupling side.

After inserting the bearing locknut, one of the tabs of the bearing lockwasher
must be bent into one of the grooves of the bearing locknut to lock them in place.

In search of a match between a tab of the washer and a slot of the locknut, the
locknut should always move forward, never backwards.
22. Insert the corresponding lip seal into coupling side bearing housing.
Figure 8.86. Inserting the corresponding lip seal into the coupling side bearing housing.
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23. Insert the coupling side bearing housing over the shaft from the coupling side until it reaches the
coupling side stuffing box.
Figure 8.87 Inserting the coupling side bearing housing over the shaft from the coupling side.
24. Place and tighten the corresponding hex bolts to secure the coupling side bearing housing to the
coupling side stuffing box.
Figure 8.88 Placing and tightening the corresponding hex bolts to secure the coupling side bearing housing to the
coupling side stuffing box.

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The tightening of the bolts must be done cross wise.
ZW
Split Case, Centrifugal Pump
25. Place and tighten the corresponding hex bolts to secure coupling side bearing cover to the coupling
side bearing housing.
Figure 8.89 Placing and tightening the corresponding hex bolts to secure the coupling side bearing cover to the
coupling side bearing housing.
26. Insert the non-coupling side stuffing box over the shaft from the non-coupling side. Arrange the
non-coupling side stuffing box with the lower casing so the screwing holes match.
Figure 8.90. Introducing the non-coupling side stuffing box into the shaft from the non-coupling side.
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27. Place and fasten (‘snug’) the corresponding screws of the non-coupling side stuffing box to secure it
to the lower casing, but do not tighten them completely. This will prevent future interference when
placing the upper casing. Make sure that the splitter is in the right place and direction, which is on
the opposite direction of the suction flange, and oriented 30° from the vertical axis.
Figure 8.91. Tightening the corresponding screws to the non-coupling side stuffing box.
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28. Insert the non-coupling side bearing bushing inside the non-coupling side bearing carrier.
Figure 8.92 Inserting the non-coupling side bearing bushing inside the non-coupling side bearing carrier.
29. Insert the corresponding set screws to secure the non-coupling side bearing bushing to the noncoupling side bearing carrier.
Figure 8.93 Inserting the corresponding set screws to secure the non-coupling side bearing bushing to the noncoupling side bearing carrier.
30. Insert the corresponding O-ring over the non-coupling side bearing carrier.
Figure 8.94 Inserting the corresponding O-ring over the non-coupling side bearing carrier.
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31. Insert the non-coupling side bearing carrier over the shaft from the non-coupling side inside the
non-coupling side stuffing box.
Figure 8.95. Inserting the non-coupling side bearing carrier over the shaft from the non-coupling side.
32. Place and tighten the corresponding hex bolts to secure the non-coupling side bearing carrier to the
non-coupling side stuffing box.
Figure 8.96 Placing and tightening the corresponding hex bolts to secure the non-coupling side bearing carrier to the
non-coupling side stuffing box.

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The tightening of the bolts must be done cross wise.
ZW
Split Case, Centrifugal Pump
33. Place the upper casing over the lower casing, making sure that the screw holes match and the Oband maintains its position.
Figure 8.97 Placing the upper casing over the lower casing, making sure that the screw holes match.

Be sure to add RTV (Room Temperature Vulcanization) silicone gasket maker in
the junction between the case and the stuffing box O-ring.
34. Place and tighten the corresponding hex bolts to secure the upper casing to the lower casing. This
should be done in a cross wise pattern like the one shown below:
Figure 8.98a Placing and tightening the corresponding hex bolts to secure the upper casing to the lower casing.
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Figure 8.98b Cross wise tightening sequence.
35. Place and tighten the rest of the hex bolts to secure the coupling side stuffing box to the upper and
lower casing.
Figure 8.99 Placing and tightening the hex bolts to secure the coupling side stuffing box to the upper and lower
casing.
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
The tightening of the bolts must be done cross wise.
36. Place and tighten the rest of the hex bolts to secure the non-coupling side stuffing box to the upper
and lower casing.
Figure 8.100 Placing and tightening the hex bolts to secure the non-coupling side stuffing box to the upper and lower
casing.

The tightening of the bolts must be done cross wise.
37. Place the corresponding lubrication tubing connectors on the coupling side of the pump.
Figure 8.101 Placing the corresponding lubrication tubing connectors on the coupling side of the pump.
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38. Place the corresponding lubrication tubing on the connectors placed in the previous step.
Figure 8.102 Placing the corresponding lubrication tubing on the connectors placed in the previous step.
39. Place the corresponding lubrication tubing connectors on the non-coupling side of the pump.
Figure 8.103 Placing the corresponding lubrication tubing connectors on the non-coupling side of the pump.
40. Place the corresponding lubrication tubing on the connectors placed in the previous step.
Figure 8.104 Placing the corresponding lubrication tubing on the connectors placed in the previous step.
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41. ZW pump vertical reassembly has been completed.
Figure 8.105 Complete ZW pump vertical reassembly.
42. Follow the steps provided in Section 4.4.2 – Vertical Pump Mounting for the proper procedure to
mount the pump on the vertical frame.
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8.3.6 ZW Packing Seal – Grease Lubrication Vertical Reassembly
15. To install the packing seal, follow these steps:
a. Insert the first set of packing strips inside the coupling side stuffing box.
Figure 8.78a. Inserting the first set of packing strips inside the coupling side stuffing box.
b. Insert the lantern ring over the shaft inside the coupling side stuffing box until it reaches the
first set of packing strips.
Figure 8.78b Inserting the lantern ring over the shaft inside the coupling side stuffing box.
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c. Insert the second set of packing strips inside the coupling side stuffing box.
Figure 8.78c Inserting the second set of packing strips inside the coupling side stuffing box.
The packing strip cuts must be done as indicated below:
•
The cut of a packing strip for valves must always be made at 45°.
•
If the stuffing box section of a centrifugal pump is equal or less than ½ in, the packing strip cut
must be made at 45°.
•
If the stuffing box section of a centrifugal pump is greater than ½ in, the packing strip cut must
be made at 90°.
Figure 8.78.d Packing strip cut at 45°(left) and 90° (right).

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The number of packing strips before and after the lantern ring may vary in order
to place the lantern ring directly below the flush line’s hole. Usually the first set
consists of three packings while the second set usually consists of two packings.
ZW
Split Case, Centrifugal Pump
Second set of packing strips.
Usually consists of two packings.
First set of packing strips.
Usually consists of three
packings.
Lantern ring placed
directly below the flush
line´s hole.
Figure 8.78.e Packing strip set and lantern ring placement.
d. Join both halves of the packing gland.
Figure 8.78.f Joining both halves of the packing gland.
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e. Insert the corresponding hex bolts to hold the two halves of the packing gland together.
Figure 8.78.g Inserting the corresponding hex bolts to hold the two halves of the packing gland together.

The hex bolts must be inserted in opposite directions.
f. Place and tighten the corresponding hex nuts to secure both halves of the packing gland
together.
Figure 8.78.h Placing and tightening the corresponding hex nuts to secure both halves of the packing gland together.
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g. Insert the packing gland assembly inside the coupling side stuffing box until it reaches the
second set of packing strips.
Figure 8.78.i Inserting the packing gland assembly inside the coupling side stuffing box.
h. Place the corresponding studs to join the packing gland to the coupling side stuffing box.
Figure 8.78.j Placing the corresponding studs to join the packing gland to the coupling side stuffing box.
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i.
Place the corresponding washers on the studs placed on the previous step.
Figure 8.78.k Placing the corresponding washers on the studs placed on the previous step.
j.
Insert and tighten the hex nuts over the packing gland studs to secure the packing gland to
the coupling side stuffing box.
Figure 8.78.l Inserting and tightening the hex nuts over the packing gland studs to secure the packing gland to the
coupling side stuffing box.
After completing the steps detailed above, refer to Section 8.3.5 ZW Mechanical Seal – Grease Lubrication
Vertical Reassembly Step 16 to continue with the rest of the ZW Packing Seal – Grease Lubrication Vertical
pump reassembly.
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8.3.7 Packing Strip Replacement Procedure
Follow the steps detailed below to correctly perform the packing strips replacement procedure on the noncoupling side.
1. Remove the packing seal flush piping.
Figure 8.105 Removing the packing seal flush piping.
2. Remove the hex bolts that join the bearing housing to the stuffing box.
Figure 8.106 Removing the hex bolts that join the bearing housing to the stuffing box.
143
V9.100319
ZW
Split Case, Centrifugal Pump
3. Rotate the bearing housing to have better access to the socket bolts that join both halves of the
packing gland together.
Figure 8.107 Rotating the bearing housing to have better access to the socket bolts that join both halves of the
packing gland together.
4. Remove the socket bolts that join both halves of the packing gland together.
Figure 8.108 Removing the socket bolts that join both halves of the packing gland together.
144
V9.100319
ZW
Split Case, Centrifugal Pump
5. Remove the hex nuts from the studs that fix the packing gland to the stuffing box.
Figure 8.109 Removing the hex nuts from the studs that fix the packing gland to the stuffing box.
6. Remove the studs that fix the packing gland to the stuffing box.
Figure 8.110 Removing the studs that fix the packing gland to the stuffing box.
145
V9.100319
ZW
Split Case, Centrifugal Pump
7. Remove the packing gland from the stuffing box. Rotate the bearing housing if needed.
Figure 8.111 Removing the packing gland from the stuffing box.

The packing gland must be separated into its two halves before removing it from
the shaft.
8. Remove the outer set of packing strips from the stuffing box.
Figure 8.112 Removing the outer set of packing strips from the stuffing box.

146
V9.100319
Separate the joints of each packing strip to remove them from the shaft.
ZW
Split Case, Centrifugal Pump
9. Remove the lantern ring from the stuffing box.
Figure 8.113 Removing the lantern ring from the stuffing box.

The lantern ring is of the split ring kind, so it can be separated in two halves to
remove it from the shaft.
10. Remove the inner set of packing strips from the stuffing box.
Figure 8.114 Removing the inner set of packing strips from the stuffing box.
147
V9.100319
ZW
Split Case, Centrifugal Pump

Use a flexible packing strip extractor to facilitate the removal of the outer and
inner sets of packing strips and the lantern ring.
Figure 8.115 Flexible packing strip extractor.
11. Insert the inner set of new packing strips inside the stuffing box.
Figure 8.116 Inserting the inner set of new packing strips inside the stuffing box.
148
V9.100319
ZW
Split Case, Centrifugal Pump
12. Insert the lantern ring inside the stuffing box.
Figure 8.117 Inserting the lantern ring inside the stuffing box.

The two halves of the split lantern ring must be joined over the shaft before
inserting them inside the stuffing box.
13. Insert the outer set of new packing strips inside the stuffing box.
Figure 8.118 Inserting the outer set of new packing strips inside the stuffing box.
149
V9.100319
ZW
Split Case, Centrifugal Pump

Make sure that the joining faces of the packing strips on the inner and outer sets
are staggered 90° between each other to ensure a proper assembly and function.
14. Join the two halves of the packing gland over the shaft and insert them inside the stuffing box until
they reach the outer set of packing strips.
Figure 8.119 Joining and inserting the two halves of the packing gland inside the stuffing box.
15. Insert the studs that hold the packing gland to the stuffing box.
Figure 8.120 Inserting the studs that hold the packing gland to the stuffing box.
150
V9.100319
ZW
Split Case, Centrifugal Pump
16. Place and tighten the hex nuts on the studs that fix the packing gland to the stuffing box.
Figure 8.121 Placing and tightening the hex nuts on the studs that fix the packing gland to the stuffing box.
17. Place the socket bolts that fix both halves of the packing gland together.
Figure 8.122 Placing the socket bolts that fix both halves of the packing gland together.
151
V9.100319
ZW
Split Case, Centrifugal Pump
18. Rotate the bearing housing to its correct position.
Figure 8.123 Rotating the bearing housing to its correct position.
19. Place and tighten the hex bolts that secure the bearing housing to the stuffing box.
Figure 8.124 Placing and tightening the hex bolts that secure the bearing housing to the stuffing box.
152
V9.100319
ZW
Split Case, Centrifugal Pump
20. Reinstall the packing seal flush piping
Figure 8.125 Reinstalling the packing seal flush piping.
21. Repeat steps 1 thru 20 on the coupling side to replace the coupling side’s packing strips.
22. The packing strip replacement procedure is complete.
153
V9.100319
ZW
Split Case, Centrifugal Pump
9. SPARE PARTS
The recommended quantity of spare parts to meet regular conditions of constant operation over a period
of two years are given in the list below:
Spare parts
Impeller
Case
wear
ring,
impeller wear ring
Number of identical pumps (including reserve pumps)
10 and
2
3
4
5
6 and 7 8 and 9
more
Quantity of spare parts
1
1
1
2
2
3
30%
2
2
2
3
3
4
50%
Shaft with fitting key
1
1
2
2
2
3
30%
Bearings
Bearing
housings
complete with shaft,
bearings, etc.
Gasket for pump
casing (Sets)
Packing rings
1
1
2
2
3
4
50%
-
-
-
-
-
1
2
4
6
8
8
9
12
150%
2
3
6
8
8
10
150%
Spring
1
1
1
1
2
2
20%
1
1
2
2
2
3
30%
Repair
Kit
mechanical seal
for
The spare parts should be available from the time of first operation.
Spare parts taken out and used must be replaced as soon as possible.
Please provide the following details when ordering:
• Order No. of the pump
154
•
Type of pump and size
•
Identity number from the list of spare parts
•
Part number from the sectional drawing
•
Quantity
V9.100319
ZW
Split Case, Centrifugal Pump
Material Storage of spare parts
• Store the spare parts in their original packaging.
155
•
Store in a dry place, preferably at a constant temperature.
•
Check the spare parts and the state of the packaging every 6 months for signs of corrosion.
•
Repair any damage or sign of corrosion with anticorrosive agents.
V9.100319
ZW
Split Case, Centrifugal Pump
10. PARTS INFORMATION
SECTIONAL DRAWING INDEX
Please identify the sectional drawing and parts list that matches your pump, according to the options
below:
CONFIGURATION
Horizontal
Horizontal
Horizontal
Horizontal
Horizontal
Horizontal
Horizontal
Horizontal
Horizontal
Horizontal
Horizontal
Horizontal
Horizontal
Horizontal
Horizontal
Horizontal
Vertical
Vertical
Vertical
Vertical
156
V9.100319
SHAFT
SEALING
Mechanical
Seal
Mechanical
Seal
Mechanical
Seal
Mechanical
Seal
Mechanical
Seal
Mechanical
Seal
Mechanical
Seal
Mechanical
Seal
Packing Strips
Packing Strips
Packing Strips
Packing Strips
Packing Strips
Packing Strips
Packing Strips
Packing Strips
Mechanical
Seal
Mechanical
Seal
Packing Strips
Packing Strips
LUBRICATION
SEAL
TYPE
IMPELLER
WEAR
RINGS
SECTIONAL
DRAWING
Grease
Lip
Without
10.1
Grease
Lip
With
10.2
Grease
Labyrinth
Without
10.3
Grease
Labyrinth
With
10.4
Oil
Lip
Without
10.5
Oil
Lip
With
10.6
Oil
Labyrinth
Without
10.7
Oil
Labyrinth
With
10.8
Grease
Grease
Grease
Grease
Oil
Oil
Oil
Oil
Lip
Lip
Labyrinth
Labyrinth
Lip
Lip
Labyrinth
Labyrinth
Without
With
Without
With
Without
With
Without
With
10.9
10.10
10.11
10.12
10.13
10.14
10.15
10.16
Grease
Lip
Without
10.17
Grease
Lip
With
10.18
Grease
Grease
Lip
Lip
Without
With
10.19
10.20
ZW
Split Case, Centrifugal Pump
10.1 ZW Pump Horizontal Sectional Drawing – Mechanical Seal, Grease Lubrication, Lip Seal, Without
Impeller Wear Rings Option
Figure 10.1 ZW Pump Horizontal Sectional Drawing – Mechanical Seal, Grease Lubrication, Lip Seal, Without Impeller
Wear Rings Option.
157
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Horizontal Mechanical Seal, Grease Lubrication, Lip Seal, Without Impeller Wear Rings
Option.
ITEM
101
211
234
270
320
350.1
350.2
360
402
412.1
412.2
412.3
412.4
158
V9.100319
DESCRIPTION
ITEM
DESCRIPTION
PUMP CASE
PUMP SHAFT
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
NON-COUPLING SIDE BEARING
HOUSING
COUPLING SIDE BEARING
HOUSING
420.1
420.2
433
441
470
SHAFT SEAL (BEARING COVER)
SHAFT SEAL (BEARING HOUSING)
MECHANICAL SEAL
STUFFING BOX
SEAL GLAND
BEARING COVER
523.1
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
O-RING (SEAL GLAND)
523.2
923
931
940.1
940.2
502
CASING WEAR RING
506
RETAINING RING
NON-COUPLING SIDE SHAFT
SLEEVE
COUPLING SIDE SHAFT SLEEVE
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
COUPLING KEY
ZW
Split Case, Centrifugal Pump
10.2 ZW Pump Horizontal Sectional Drawing – Mechanical Seal, Grease Lubrication, Lip Seal, With Impeller
Wear Rings Option
Figure 10.2 ZW Pump Horizontal Sectional Drawing – Mechanical Seal, Grease Lubrication, Lip Seal, With Impeller
Wear Rings Option.
159
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Horizontal Mechanical Seal, Grease Lubrication, Lip Seal, With Impeller Wear Rings
Option.
ITEM
101
PUMP CASING
211
234
270
320
PUMP SHAFT
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
NON-COUPLING SIDE BEARING
HOUSING
COUPLING SIDE BEARING
HOUSING
350.1
350.2
360
402
412.1
412.2
412.3
412.4
420.1
160
V9.100319
DESCRIPTION
ITEM
DESCRIPTION
433
441
470
502
SHAFT SEAL (BEARING
HOUSING)
MECHANICAL SEAL
STUFFING BOX
SEAL GLAND
CASING WEAR RING
503
IMPELLER WEAR RING
506
RETAINING RING
420.2
BEARING COVER
523.1
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
O-RING (SEAL GLAND)
SHAFT SEAL (BEARING COVER)
523.2
923
931
940.1
940.2
NON-COUPLING SIDE SHAFT
SLEEVE
COUPLING SIDE SHAFT SLEEVE
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
COUPLING KEY
ZW
Split Case, Centrifugal Pump
10.3 ZW Pump Horizontal Sectional Drawing – Mechanical Seal, Grease Lubrication, Labyrinth Seal, Without
Impeller Wear Rings Option
Figure 10.3 ZW Pump Horizontal Sectional Drawing – Mechanical Seal, Grease Lubrication, Labyrinth Seal, Without
Impeller Wear Rings Option.
161
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Horizontal Mechanical Seal, Grease Lubrication, Labyrinth Seal, Without Impeller Wear
Rings Option.
ITEM
433
441
470
502
CASING WEAR RING
506
RETAINING RING
423.1
211
PUMP SHAFT
423.2
234
270
320
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
NON-COUPLING SIDE BEARING
HOUSING
COUPLING SIDE BEARING
HOUSING
360
402
412.1
412.2
412.3
412.4
DESCRIPTION
LABYRINTH SEAL (BEARING
COVER)
LABYRINTH SEAL (BEARING
HOUSING)
MECHANICAL SEAL
STUFFING BOX
SEAL GLAND
PUMP CASE
350.2
V9.100319
ITEM
101
350.1
162
DESCRIPTION
BEARING COVER
523.1
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
O-RING (SEAL GLAND)
523.2
923
931
940.1
940.2
NON-COUPLING SIDE SHAFT
SLEEVE
COUPLING SIDE SHAFT SLEEVE
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
COUPLING KEY
ZW
Split Case, Centrifugal Pump
10.4 ZW Pump Horizontal Sectional Drawing – Mechanical Seal, Grease Lubrication, Labyrinth Seal, With
Impeller Wear Rings Option
Figure 10.4 ZW Pump Horizontal Sectional Drawing – Mechanical Seal, Grease Lubrication, Labyrinth Seal, With
Impeller Wear Rings Option.
163
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Horizontal Mechanical Seal, Grease Lubrication, Labyrinth Seal, With Impeller Wear
Rings Option.
ITEM
101
PUMP CASING
211
234
270
320
PUMP SHAFT
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
NON-COUPLING SIDE BEARING
HOUSING
COUPLING SIDE BEARING
HOUSING
350.1
350.2
360
402
412.1
412.2
412.3
412.4
423.1
164
V9.100319
DESCRIPTION
ITEM
DESCRIPTION
433
441
470
502
LABYRINTH SEAL (BEARING
HOUSING)
MECHANICAL SEAL
STUFFING BOX
SEAL GLAND
CASING WEAR RING
503
IMPELLER WEAR RING
506
RETAINING RING
423.2
BEARING COVER
523.1
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
O-RING (SEAL GLAND)
LABYRINTH SEAL (BEARING
COVER)
523.2
923
931
940.1
940.2
NON-COUPLING SIDE SHAFT
SLEEVE
COUPLING SIDE SHAFT SLEEVE
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
COUPLING KEY
ZW
Split Case, Centrifugal Pump
10.5 ZW Pump Horizontal Sectional Drawing – Mechanical Seal, Oil Lubrication, Lip Seal, Without Impeller
Wear Rings Option
Figure 10.5 ZW Pump Horizontal Sectional Drawing – Mechanical Seal, Oil Lubrication, Lip Seal, Without Impeller
Wear Rings Option.
165
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Horizontal Mechanical Seal, Oil Lubrication, Lip Seal, Without Impeller Wear Rings
Option.
ITEM
101
211
234
270
320
350.1
350.2
360
402
412.1
412.2
412.3
412.4
420.1
166
V9.100319
DESCRIPTION
PUMP CASE
PUMP SHAFT
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
NON-COUPLING SIDE BEARING
HOUSING
COUPLING SIDE BEARING
HOUSING
BEARING COVER
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
O-RING (SEAL GLAND)
SHAFT SEAL (BEARING COVER)
ITEM
DESCRIPTION
420.2
433
441
470
502
SHAFT SEAL (BEARING HOUSING)
MECHANICAL SEAL
STUFFING BOX
SEAL GLAND
CASING WEAR RING
506
523.1
523.2
638
923
931
940.1
940.2
RETAINING RING
NON-COUPLING SIDE SHAFT
SLEEVE
COUPLING SIDE SHAFT SLEEVE
CONSTANT LEVEL OILER
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
COUPLING KEY
ZW
Split Case, Centrifugal Pump
10.6 ZW Pump Horizontal Sectional Drawing – Mechanical Seal, Oil Lubrication, Lip Seal, With Impeller
Wear Rings Option
Figure 10.6 ZW Pump Horizontal Sectional Drawing – Mechanical Seal, Oil Lubrication, Lip Seal, With Impeller Wear
Rings Option.
167
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Horizontal Mechanical Seal, Oil Lubrication, Lip Seal, With Impeller Wear Rings Option.
ITEM
101
PUMP CASING
211
234
270
320
PUMP SHAFT
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
NON-COUPLING SIDE BEARING
HOUSING
COUPLING SIDE BEARING
HOUSING
350.1
350.2
360
402
412.1
412.2
412.3
412.4
420.1
168
V9.100319
DESCRIPTION
ITEM
DESCRIPTION
433
441
470
502
SHAFT SEAL (BEARING
HOUSING)
MECHANICAL SEAL
STUFFING BOX
SEAL GLAND
CASING WEAR RING
503
IMPELLER WEAR RING
506
RETAINING RING
420.2
BEARING COVER
523.1
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
O-RING (SEAL GLAND)
SHAFT SEAL (BEARING COVER)
523.2
638
923
931
940.1
940.2
NON-COUPLING SIDE SHAFT
SLEEVE
COUPLING SIDE SHAFT SLEEVE
CONSTANT LEVEL OILER
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
COUPLING KEY
ZW
Split Case, Centrifugal Pump
10.7 ZW Pump Horizontal Sectional Drawing – Mechanical Seal, Oil Lubrication, Labyrinth Seal, Without
Impeller Wear Rings Option
Figure 10.7 ZW Pump Horizontal Sectional Drawing – Mechanical Seal, Oil Lubrication, Labyrinth Seal, Without
Impeller Wear Rings Option.
169
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Horizontal Mechanical Seal, Oil Lubrication, Labyrinth Seal, Without Impeller Wear
Rings Option.
ITEM
101
PUMP CASE
211
234
270
320
PUMP SHAFT
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
NON-COUPLING SIDE BEARING
HOUSING
COUPLING SIDE BEARING
HOUSING
BEARING COVER
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
O-RING (SEAL GLAND)
LABYRINTH SEAL (BEARING
COVER)
350.1
350.2
360
402
412.1
412.2
412.3
412.4
423.1
170
V9.100319
DESCRIPTION
ITEM
DESCRIPTION
433
441
470
502
LABYRINTH SEAL (BEARING
HOUSING)
MECHANICAL SEAL
STUFFING BOX
SEAL GLAND
CASING WEAR RING
506
RETAINING RING
423.2
523.1
523.2
638
923
931
940.1
940.2
NON-COUPLING SIDE SHAFT
SLEEVE
COUPLING SIDE SHAFT SLEEVE
CONSTANT LEVEL OILER
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
COUPLING KEY
ZW
Split Case, Centrifugal Pump
10.8 ZW Pump Horizontal Sectional Drawing – Mechanical Seal, Oil Lubrication, Labyrinth Seal, With
Impeller Wear Rings Option
Figure 10.8 ZW Pump Horizontal Sectional Drawing – Mechanical Seal, Oil Lubrication, Labyrinth Seal, With Impeller
Wear Rings Option.
171
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Horizontal Mechanical Seal, Oil Lubrication, Labyrinth Seal, With Impeller Wear Rings
Option.
ITEM
101
PUMP CASING
211
234
270
320
PUMP SHAFT
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
NON-COUPLING SIDE BEARING
HOUSING
COUPLING SIDE BEARING
HOUSING
350.1
350.2
360
402
412.1
412.2
412.3
412.4
423.1
172
V9.100319
DESCRIPTION
ITEM
DESCRIPTION
433
441
470
502
LABYRINTH SEAL (BEARING
HOUSING)
MECHANICAL SEAL
STUFFING BOX
SEAL GLAND
CASING WEAR RING
503
IMPELLER WEAR RING
506
RETAINING RING
423.2
BEARING COVER
523.1
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
O-RING (SEAL GLAND)
LABYRINTH SEAL (BEARING
COVER)
523.2
638
923
931
940.1
NON-COUPLING SIDE SHAFT
SLEEVE
COUPLING SIDE SHAFT SLEEVE
CONSTANT LEVEL OILER
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
940.2
COUPLING KEY
ZW
Split Case, Centrifugal Pump
10.9 ZW Pump Horizontal Sectional Drawing – Packing Strips Seal, Grease Lubrication, Lip Seal, Without
Impeller Wear Rings Option
Figure 10.9 ZW Pump Horizontal Sectional Drawing – Packing Strips Seal, Grease Lubrication, Lip Seal, Without
Impeller Wear Rings Option.
173
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Horizontal Packing Strips Seal, Grease Lubrication, Lip Seal, Without Impeller Wear
Rings Option.
ITEM
101
211
234
270
320
350.1
350.2
360
402
412.1
412.2
412.3
420.1
174
V9.100319
DESCRIPTION
PUMP CASE
PUMP SHAFT
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
NON-COUPLING SIDE BEARING
HOUSING
COUPLING SIDE BEARING
HOUSING
BEARING COVER
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
SHAFT SEAL (BEARING COVER)
ITEM
DESCRIPTION
420.2
441
458
461
502
SHAFT SEAL (BEARING HOUSING)
STUFFING BOX
LANTERN RING
PACKING GLAND
CASING WEAR RING
506
523.1
523.2
551
923
931
940.1
940.2
RETAINING RING
NON-COUPLING SIDE SHAFT
SLEEVE
COUPLING SIDE SHAFT SLEEVE
DISC SPACER
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
COUPLING KEY
ZW
Split Case, Centrifugal Pump
10.10 ZW Pump Horizontal Sectional Drawing – Packing Strips Seal, Grease Lubrication, Lip Seal, With
Impeller Wear Rings Option
Figure 10.10 ZW Pump Horizontal Sectional Drawing – Packing Strips Seal, Grease Lubrication, Lip Seal, With Impeller
Wear Rings Option.
175
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Horizontal Packing Strips Seal, Grease Lubrication, Lip Seal, With Impeller Wear Rings
Option.
ITEM
101
211
234
270
320
350.1
350.2
360
402
412.1
412.2
412.3
420.1
420.2
176
V9.100319
DESCRIPTION
PUMP CASING
PUMP SHAFT
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
NON-COUPLING SIDE BEARING
HOUSING
COUPLING SIDE BEARING
HOUSING
BEARING COVER
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
SHAFT SEAL (BEARING COVER)
SHAFT SEAL (BEARING
HOUSING)
ITEM
DESCRIPTION
441
458
461
502
503
STUFFING BOX
LANTERN RING
PACKING GLAND
CASING WEAR RING
IMPELLER WEAR RING
506
RETAINING RING
523.1
523.2
551
923
931
940.1
940.2
NON-COUPLING SIDE SHAFT
SLEEVE
COUPLING SIDE SHAFT SLEEVE
DISC SPACER
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
COUPLING KEY
ZW
Split Case, Centrifugal Pump
10.11 ZW Pump Horizontal Sectional Drawing – Packing Strips Seal, Grease Lubrication, Labyrinth Seal,
Without Impeller Wear Rings Option
Figure 10.11 ZW Pump Horizontal Sectional Drawing – Packing Strips Seal, Grease Lubrication, Labyrinth Seal,
Without Impeller Wear Rings Option.
177
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Horizontal Packing Strips Seal, Grease Lubrication, Labyrinth Seal, Without Impeller
Wear Rings Option.
ITEM
101
PUMP CASE
211
234
270
320
PUMP SHAFT
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
NON-COUPLING SIDE BEARING
HOUSING
COUPLING SIDE BEARING
HOUSING
BEARING COVER
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
LABYRINTH SEAL (BEARING
COVER)
350.1
350.2
360
402
412.1
412.2
412.3
423.1
178
V9.100319
DESCRIPTION
ITEM
DESCRIPTION
441
458
461
502
LABYRINTH SEAL (BEARING
HOUSING)
STUFFING BOX
LANTERN RING
PACKING GLAND
CASING WEAR RING
506
RETAINING RING
423.2
523.2
551
923
931
940.1
NON-COUPLING SIDE SHAFT
SLEEVE
COUPLING SIDE SHAFT SLEEVE
DISC SPACER
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
940.2
COUPLING KEY
523.1
ZW
Split Case, Centrifugal Pump
10.12 ZW Pump Horizontal Sectional Drawing – Packing Strips Seal, Grease Lubrication, Labyrinth Seal, With
Impeller Wear Rings Option
Figure 10.12 ZW Pump Horizontal Sectional Drawing – Packing Strips Seal, Grease Lubrication, Labyrinth Seal, With
Impeller Wear Rings Option.
179
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Horizontal Packing Strips Seal, Grease Lubrication, Labyrinth Seal, With Impeller Wear
Rings Option.
ITEM
101
211
234
270
320
350.1
350.2
360
402
412.1
412.2
412.3
423.1
423.2
180
V9.100319
DESCRIPTION
PUMP CASING
PUMP SHAFT
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
NON-COUPLING SIDE BEARING
HOUSING
COUPLING SIDE BEARING
HOUSING
BEARING COVER
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
LABYRINTH SEAL (BEARING
COVER)
LABYRINTH SEAL (BEARING
HOUSING)
ITEM
DESCRIPTION
441
458
461
502
503
STUFFING BOX
LANTERN RING
PACKING GLAND
CASING WEAR RING
IMPELLER WEAR RING
506
RETAINING RING
523.2
551
923
931
940.1
NON-COUPLING SIDE SHAFT
SLEEVE
COUPLING SIDE SHAFT SLEEVE
DISC SPACER
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
940.2
COUPLING KEY
523.1
ZW
Split Case, Centrifugal Pump
10.13 ZW Pump Horizontal Sectional Drawing – Packing Strips Seal, Oil Lubrication, Lip Seal, Without
Impeller Wear Rings Option
Figure 10.13 ZW Pump Horizontal Sectional Drawing – Packing Strips Seal, Oil Lubrication, Lip Seal, Without Impeller
Wear Rings Option.
181
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Horizontal Packing Strips Seal, Oil Lubrication, Lip Seal, Without Impeller Wear Rings
Option.
ITEM
101
211
234
270
320
350.1
350.2
360
402
412.1
412.2
412.3
420.1
420.2
182
V9.100319
DESCRIPTION
PUMP CASE
PUMP SHAFT
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
NON-COUPLING SIDE BEARING
HOUSING
COUPLING SIDE BEARING
HOUSING
BEARING COVER
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
SHAFT SEAL (BEARING COVER)
SHAFT SEAL (BEARING
HOUSING)
ITEM
441
458
461
502
506
523.1
DESCRIPTION
STUFFING BOX
LANTERN RING
PACKING GLAND
CASING WEAR RING
RETAINING RING
NON-COUPLING SIDE SHAFT
SLEEVE
523.2
COUPLING SIDE SHAFT SLEEVE
551
638
923
931
940.1
940.2
DISC SPACER
CONSTANT LEVEL OILER
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
COUPLING KEY
ZW
Split Case, Centrifugal Pump
10.14 ZW Pump Horizontal Sectional Drawing – Packing Strips Seal, Oil Lubrication, Lip Seal, With Impeller
Wear Rings Option
Figure 10.14 ZW Pump Horizontal Sectional Drawing – Packing Strips Seal, Oil Lubrication, Lip Seal, With Impeller
Wear Rings Option.
183
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Horizontal Packing Strips Seal, Oil Lubrication, Lip Seal, With Impeller Wear Rings
Option.
ITEM
101
211
234
270
320
350.1
350.2
360
402
412.1
412.2
412.3
420.1
420.2
184
V9.100319
DESCRIPTION
PUMP CASING
PUMP SHAFT
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
NON-COUPLING SIDE BEARING
HOUSING
COUPLING SIDE BEARING
HOUSING
BEARING COVER
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
SHAFT SEAL (BEARING COVER)
SHAFT SEAL (BEARING
HOUSING)
ITEM
DESCRIPTION
441
458
461
502
503
STUFFING BOX
LANTERN RING
PACKING GLAND
CASING WEAR RING
IMPELLER WEAR RING
506
RETAINING RING
523.2
551
638
923
931
940.1
NON-COUPLING SIDE SHAFT
SLEEVE
COUPLING SIDE SHAFT SLEEVE
DISC SPACER
CONSTANT LEVEL OILER
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
940.2
COUPLING KEY
523.1
ZW
Split Case, Centrifugal Pump
10.15 ZW Pump Horizontal Sectional Drawing – Packing Strips Seal, Oil Lubrication, Labyrinth Seal, Without
Impeller Wear Rings Option
Figure 10.15 ZW Pump Horizontal Sectional Drawing – Packing Strips Seal, Oil Lubrication, Labyrinth Seal, Without
Impeller Wear Rings Option.
185
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Horizontal Packing Strips Seal, Oil Lubrication, Labyrinth Seal, Without Impeller Wear
Rings Option.
ITEM
101
211
234
270
320
350.1
350.2
360
402
412.1
412.2
412.3
423.1
423.2
186
V9.100319
DESCRIPTION
PUMP CASE
PUMP SHAFT
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
NON-COUPLING SIDE BEARING
HOUSING
COUPLING SIDE BEARING
HOUSING
BEARING COVER
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
LABYRINTH SEAL (BEARING
COVER)
LABYRINTH SEAL (BEARING
HOUSING)
ITEM
441
458
461
502
506
523.1
DESCRIPTION
STUFFING BOX
LANTERN RING
PACKING GLAND
CASING WEAR RING
RETAINING RING
NON-COUPLING SIDE SHAFT
SLEEVE
523.2
COUPLING SIDE SHAFT SLEEVE
551
638
923
931
940.1
DISC SPACER
CONSTANT LEVEL OILER
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
940.2
COUPLING KEY
ZW
Split Case, Centrifugal Pump
10.16 ZW Pump Horizontal Sectional Drawing – Packing Strips Seal, Oil Lubrication, Labyrinth Seal, With
Impeller Wear Rings Option
Figure 10.16 ZW Pump Horizontal Sectional Drawing – Packing Strips Seal, Oil Lubrication, Labyrinth Seal, With
Impeller Wear Rings Option.
187
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Horizontal Packing Strips Seal, Oil Lubrication, Labyrinth Seal, With Impeller Wear Rings
Option.
ITEM
101
211
234
270
320
350.1
350.2
360
402
412.1
412.2
412.3
423.1
423.2
188
V9.100319
DESCRIPTION
PUMP CASING
PUMP SHAFT
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
NON-COUPLING SIDE BEARING
HOUSING
COUPLING SIDE BEARING
HOUSING
BEARING COVER
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
LABYRINTH SEAL (BEARING
COVER)
LABYRINTH SEAL (BEARING
HOUSING)
ITEM
DESCRIPTION
441
458
461
502
503
STUFFING BOX
LANTERN RING
PACKING GLAND
CASING WEAR RING
IMPELLER WEAR RING
506
RETAINING RING
523.2
551
638
923
931
NON-COUPLING SIDE SHAFT
SLEEVE
COUPLING SIDE SHAFT SLEEVE
DISC SPACER
CONSTANT LEVEL OILER
BEARING LOCKNUT
BEARING LOCKWASHER
940.1
IMPELLER KEY
940.2
COUPLING KEY
523.1
ZW
Split Case, Centrifugal Pump
10.17 ZW Pump Vertical Sectional Drawing – Mechanical Seal, Grease Lubrication, Lip Seal, Without
Impeller Wear Rings Option
Figure 10.17 ZW Pump Vertical Sectional Drawing – Mechanical Seal, Grease Lubrication, Lip Seal, Without Impeller
Wear Rings Option.
189
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Vertical Mechanical Seal, Grease Lubrication, Lip Seal, Without Impeller Wear Rings
Option.
ITEM
V9.100319
ITEM
101
PUMP CASING
420.2
211
234
PUMP SHAFT
DOUBLE ENTRY IMPELLER
433
441.1
270
DEFLECTOR
441.2
320
350
360
382
ANTI-FRICTION BEARING
BEARING HOUSING
BEARING COVER
BEARING CARRIER
470
502
506
523.1
402
PLASTIC SEALING (O-BAND)
523.2
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
O-RING (SEAL GLAND)
O-RING (BEARING CARRIER)
SHAFT SEAL (BEARING COVER)
545
923
931
940.1
940.2
412.1
412.2
412.3
412.4
412.5
420.1
190
DESCRIPTION
DESCRIPTION
SHAFT SEAL (BEARING
HOUSING)
MECHANICAL SEAL
STUFFING BOX (COUPLING SIDE)
STUFFING BOX (NON-COUPLING
SIDE)
SEAL GLAND
CASING WEAR RING
RETAINING RING
COUPLING SIDE SHAFT SLEEVE
NON-COUPLING SIDE SHAFT
SLEEVE
BEARING BUSHING
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
COUPLING KEY
ZW
Split Case, Centrifugal Pump
10.18 ZW Pump Vertical Sectional Drawing – Mechanical Seal, Grease Lubrication, Lip Seal, With Impeller
Wear Rings Option
Figure 10.18 ZW Pump Vertical Sectional Drawing – Mechanical Seal, Grease Lubrication, Lip Seal, With Impeller Wear
Rings Option.
191
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Vertical Mechanical Seal, Grease Lubrication, Lip Seal, With Impeller Wear Rings Option.
ITEM
DESCRIPTION
PUMP CASING
PUMP SHAFT
DOUBLE ENTRY IMPELLER
420.2
433
441.1
270
DEFLECTOR
441.2
ANTI-FRICTION BEARING
BEARING HOUSING
BEARING COVER
BEARING CARRIER
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
O-RING (SEAL GLAND)
O-RING (BEARING CARRIER)
SHAFT SEAL (BEARING
COVER)
470
502
503
506
523.1
523.2
545
923
931
940.1
SHAFT SEAL (BEARING HOUSING)
MECHANICAL SEAL
COUPLING SIDE STUFFING BOX
NON-COUPLING SIDE STUFFING
BOX
SEAL GLAND
CASING WEAR RING
IMPELLER WEAR RING
RETAINING RING
NON-COUPLING SIDE SHAFT SLEEVE
COUPLING SIDE SHAFT SLEEVE
BEARING BUSHING
BEARING LOCKNUT
BEARING LOCKWASHER
KEY (IMPELLER)
940.2
KEY (COUPLING)
420.1
V9.100319
ITEM
101
211
234
320
350
360
382
402
412.1
412.2
412.3
412.4
412.5
192
DESCRIPTION
ZW
Split Case, Centrifugal Pump
10.19 ZW Pump Vertical Sectional Drawing – Packing Seal, Grease Lubrication, Lip Seal, Without Impeller
Wear Rings Option
Figure 10.19 ZW Pump Vertical Sectional Drawing – Packing Seal, Grease Lubrication, Lip Seal, Without Impeller Wear
Rings Option.
193
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Vertical Packing Seal, Grease Lubrication, Lip Seal, Without Impeller Wear Rings Option.
ITEM
V9.100319
ITEM
DESCRIPTION
SHAFT SEAL (BEARING HOUSING)
STUFFING BOX (COUPLING SIDE)
STUFFING BOX (NON-COUPLING
SIDE)
LANTERN RING
PACKING GLAND
CASING WEAR RING
RETAINING RING
NON-COUPLING SIDE SHAFT
SLEEVE
COUPLING SIDE SHAFT SLEEVE
BEARING BUSHING
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
COUPLING KEY
101
211
PUMP CASE
PUMP SHAFT
420.2
441.1
234
DOUBLE ENTRY IMPELLER
441.2
270
320
350
360
DEFLECTOR
ANTI-FRICTION BEARING
BEARING HOUSING
BEARING COVER
458
461
502
506
382
BEARING CARRIER
523.1
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
O-RING (BEARING HOUSING)
SHAFT SEAL (BEARING COVER)
523.2
545
923
931
940.1
940.2
402
412.1
412.2
412.3
412.4
420.1
194
DESCRIPTION
ZW
Split Case, Centrifugal Pump
10.20 ZW Pump Vertical Sectional Drawing – Packing Seal, Grease Lubrication, Lip Seal, With Impeller Wear
Rings Option
Figure 10.20 ZW Pump Vertical Sectional Drawing – Packing Seal, Grease Lubrication, Lip Seal, With Impeller Wear
Rings Option.
195
V9.100319
ZW
Split Case, Centrifugal Pump
Parts List ZW Pump Vertical Packing Seal, Grease Lubrication, Lip Seal, With Impeller Wear Rings Option.
ITEM
DESCRIPTION
STUFFING BOX (COUPLING SIDE)
STUFFING BOX (NON-COUPLING
SIDE)
LANTERN RING
PACKING GLAND
CASING WEAR RING
IMPELLER WEAR RING
RETAINING RING
NON-COUPLING SIDE SHAFT
SLEEVE
COUPLING SIDE SHAFT SLEEVE
BEARING BUSHING
BEARING LOCKNUT
BEARING LOCKWASHER
IMPELLER KEY
COUPLING KEY
PUMP CASING
441.1
211
PUMP SHAFT
441.2
234
270
320
350
360
DOUBLE ENTRY IMPELLER
DEFLECTOR
ANTI-FRICTION BEARING
BEARING HOUSING
BEARING COVER
382
BEARING CARRIER
523.1
PLASTIC SEALING (O-BAND)
O-RING (SLEEVE)
O-RING (STUFFING BOX)
O-RING (BEARING HOUSING)
O-RING (BEARING CARRIER)
SHAFT SEAL (BEARING COVER)
SHAFT SEAL (BEARING
HOUSING)
523.2
545
923
931
940.1
940.2
420.2
V9.100319
ITEM
101
402
412.1
412.2
412.3
412.4
420.1
196
DESCRIPTION
458
461
502
503
506
ZW
Split Case, Centrifugal Pump
11. TROUBLESHOOTING CHART
TROUBLE
HOT BEARINGS
PUMP DOES
NOT DELIVER
LIQUID
197
V9.100319
PROBABLE CAUSES
a. Insufficient oil
b. Contaminated oil
c. Misalignment.
d. Too much oil/grease.
e. Pump is under tension
stress.
f. The given half-coupling
spacing is not set.
g. Bearings are damaged.
a. Inner pump parts are
worn.
b. Density or viscosity of
pumped fluid is not
same as designed.
c. The motor voltage is
incorrect.
d. Motor runs only in two
phase mode.
e. Pump not primed.
f. Speed too low.
g. Feed pipe or impeller
plugged.
h. Clogged suction.
i. Damaged impeller.
j. Wrong rotation.
k. Pump or piping are not
properly vented.
l. Formation of air
pockets in the piping.
m. The counter pressure
of the system is greater
than the design point
of the pump.
n. NPSHa too low.
SUGGESTED SOLUTION
a. Add oil.
b. Drain and clean reservoir. Refill with clean oil.
c. Check alignment of pump and driver.
d. Drain to proper level. Remove excess.
e. Check the piping for tension free connections.
f. Reset and give the correct spacing.
g. Change damaged bearings.
a. Change worn parts.
b. Consult a Ruhrpumpen dealer.
c. Apply correct voltage to the motor.
d. Check the cables, connections and fuses.
e. Prime pump.
f. Check driver input.
g. Clean pipe and impeller.
h. Clean out suction line.
i. Replace impeller.
j. Check driver rotation.
k. Vent or top up.
l. Install vent valve or lay piping elsewhere.
m. Open discharge valve as wide as necessary to reach
the operating point.
n. Check the fluid level in the feed container.
Open suction valve completely.
Lay suction pipe elsewhere is friction losses are too
big.
Check for a possible filter in the feed pipe.
ZW
Split Case, Centrifugal Pump
TROUBLE
PROBABLE CAUSES
a. Air leaks into suction.
b. Speed too low.
c. Clogged suction.
d. Clogged impeller.
e. Damaged impeller.
f. Wrong rotation.
g. Pump or piping are not
properly vented.
h. Feed pipe or impeller
plugged.
CAPACITY OR
i. Formation of air
DISCHARGE
pockets in the piping.
PRESSURE LOW
j. Inner pump parts are
worn.
k. Density or viscosity of
pumped fluid is not
same as designed.
l. The motor voltage is
incorrect.
m. Motor connected only
in two-phase mode.
n. NPSHa too low.
a. Density or viscosity of
pumped fluid is not
same as designed.
b. Speed too high.
c. Pump unit is not
properly aligned.
DRIVER
d. Pump is under tension.
OVERLOAD
e. The motor voltage is
incorrect.
f. Motor connected only
in two-phase mode.
g. Bearings are damaged.
h. System head lower
than rating.
198
V9.100319
SUGGESTED SOLUTION
a. Check suction line for leaks.
b. Check driver and its power source.
c. Clean out suction line.
d. Clean impeller.
e. Replace impeller.
f. Check driver rotation.
g. Vent or top up.
h. Clean pipe and impeller.
i. Install vent valve or lay piping elsewhere.
j. Change worn parts.
k. Consult a Ruhrpumpen dealer.
l. Apply correct voltage to the motor.
m. Check the cables, connections and fuses.
n. Check the fluid level in the feed container.
Open suction valve completely.
Lay suction pipe elsewhere if friction losses are too
big.
Check for a possible filter in the feed pipe.
a. Consult a Ruhrpumpen dealer.
b. Decrease driver speed.
c. Realign the pump.
d. Check the piping for tension free connections.
e. Apply correct voltage to the motor.
f. Check the cables, connections and fuses.
g. Change damaged bearings.
h. Check suction and discharge pressure.
Set operating point with the discharge valve.
ZW
Split Case, Centrifugal Pump
RUHRPUMPEN PLANTS
PLA USA, Tulsa & Orland
MEXICO, Monterrey
BRAZIL, Río De Janeiro
ARGENTINA, Buenos Aires
GERMANY, Witten
EGYPT, Suez
INDIA, Chennai
CHINA, Changzhou
UK, Lancing
V9.100319
199
V9.100319
^d/KEϮ
Global Proposal System 20.0.5
Pump Performance Datasheet
Customer
Customer reference
Item number
Service
Quantity
: PAN AMERICAN ENERGY LLC S. ARG.
:
: 001
: Diesel fire pump
:1
Operating Conditions
Flow, rated
: 4,000.0 (6,000.0)
USgpm
Differential head / pressure, rated (requested) : 160.0 (146.4) psi
Differential head / pressure, rated (actual)
: 160.2 psi
Suction pressure, rated / max
: 0.00 / 0.00 psi.g
NPSH available, rated
: Ample
Frequency
: 60 Hz
Performance
Speed, rated
: 1750 rpm
Impeller diameter, rated
: 19.25 in
Impeller diameter, maximum
: 24.41 in
Impeller diameter, minimum
: 18.74 in
Efficiency
: 75.5 (84.7) %
NPSH required / margin required
: 15.79 (15.73) / 0.00 ft
Ns (imp. eye flow) / Nss (imp. eye flow)
: 1,063 / 11,655 US Units
MCSF
: 2,784.2 USgpm
Head, maximum, rated diameter
: 176.5 psi
Head rise to shutoff
: 10.18 (20.58) %
Flow, best eff. point
: 6,892.5 USgpm
Flow ratio, rated / BEP
: 58.03 (87.05) %
Diameter ratio (rated / max)
: 78.87 %
Head ratio (rated dia / max dia)
: 60.63 %
Cq/Ch/Ce/Cn [ANSI/HI 9.6.7-2010]
: 1.00 / 1.00 / 1.00 / 1.00
Selection status
: Acceptable
Quote number
Size
Stages
Based on curve number
Date last saved
: 1078449 - Rev 3
: ZW 14x10x24 (F)
:1
: 75081_ZW_14x10x24_F_4.50.03
: 04/03/2020 12:46 AM
Liquid
Liquid type
: Fire-fighting water
Additional liquid description
:
Solids diameter, max
: 0.00 in
Solids concentration, by volume
: 0.00 %
Temperature, max
: 68.00 deg F
Fluid density, rated / max
: 1.000 / 1.000 SG
Viscosity, rated
: 1.00 cP
Vapor pressure, rated
: 0.34 psi.a
Pressure Data
Maximum discharge pressure
: 176.5 psi.g
Maximum allowable working pressure
: 176.5 psi.g
Maximum allowable suction pressure
: 0.00 psi.g
Hydrostatic test pressure
: 250.0 psi.g
Driver & Power Data (@Max density)
Driver sizing specification
: Rated power
Margin over specification
: 0.00 %
Service factor
: 1.00
Power, hydraulic
: 374 (512) hp
Power, rated
: 495 (605) hp
Power, maximum, rated diameter
: 671 hp
Minimum recommended motor rating
: 500 hp / 373 kW
Power - hp
800
Power
600
400
200
0
400
360
320
24.41 in
Head - psi
280
240
200
19.25 in
160
18.74 in
120
80
40
NPSHr - ft
0
40
NPSHr
20
0
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
Flow - USgpm
8,000
9,000
10,000
11,000
12,000
13,000
BILL OF MATERIALS
PUMP DESCRIPTION: ZW 14X10X24
Level
Part Number
1
CUS 24900920
Quantity
1.00 ea
24014912
PMP ZW 14X10X24F
1.00 ea
26022424
A CASE ZW 14X10X24
1.00 ea
26017483
SA STF BOX ZW 14X10X24
A 48 Cl. 35B
1.00 ea
5
16003945
STF BOX ZW S100 115
A 48 Cl. 35B
2.00 ea
5
60012845
ORNG 320X8MT 568
-
2.00 ea
5
73007180
HEX BLT 16X40MT 3G4
5
73003428
SCK PLUG 3/8 NPT 354
A 105
6.00 ea
5
72006252
MALE CNCT 1/2X3/8 NPT 350
A 479 Ty 316 - UNS S31600
2.00 ea
26022425
SA CASE ZW 14X20X24
A 48 Cl. 35B
1.00 ea
14007699
CASE ZW 14X10X24 115
A 48 Cl. 35B
1.00 ea
73007546
HEX BLT 30X60MT 3G4
A 193 Gr. B7 (A3B)
23000880
CASE ALGNR 13X25X10MT 301
A 576 Gr. 1045 - UNS G104
2.00 ea
5
60008750
CORD 8MT 568
-
3.96 m
5
67015888
CASE WR 323MT 225
A 744 Gr. CD4MCu
2.00 ea
5
73006118
EYE BLT 16X20MT 604
A 489
2.00 ea
5
73002727
SQR PLUG 1NPT 908
AISI 316
2.00 ea
5
78000078
NAMEPLT ROTATION 903
-
1.00 ea
5
73002807
SQR PLUG 1/4NPT 908
AISI 316
2.00 ea
5
73006652
SQR PLUG 1 1/2NPT 319
A 193 Gr. B8M Cl. 1 - UNS
2.00 ea
5
73005922
SQR SET SCRW 16X50MT 897
SAE J429 Gr. 5
2.00 ea
5
72001429
MALE CNCT 1/2X1/2NPT 908
AISI 316
2.00 ea
5
74005995
PLN WSH 33X55X5MT 902
Carbon Steel
5
73002726
SQR PLUG 1/2 14NPT 908
AISI 316
1.00 ea
5
73010818
SCK SET SCRW 10X20MT 908
AISI 316
4.00 ea
26007149
A SEAL ZW S100
1.00 ea
82002011
KIT PACK ZW S100
1.00 ea
5
60002344
PACK 5/8 936
PTFE
5
71005197
LNTR RNG ZW 100MT 139
A 351 Gr. CF8M - UNS J929
2.00 ea
5
62000500
PACK GLND ZW S100 139
A 351 Gr. CF8M - UNS J929
4.00 ea
5
73007340
SCK BLT 8X40MT 320
5
73010530
5
3
4
4
5
3
4
8/21/2020
Material
153200083
BS PMP ZW 14X10X24F
2
3
Part Description
PROJECT:
*A 193 Gr. B7 (A3B)
24.00 ea
24.00 ea
24.00 ea
135.00 in
*A 193 Gr. B8M Cl. 2 - UNS
4.00 ea
CONT STUD 16X80MT 320
A 193 Gr. B8M Cl. 2 - UNS
4.00 ea
74001283
PLN WSH 16MT 908
AISI 316
4.00 ea
5
74001282
HEX NUT 16MT 886
F 594 Alloy 304 - UNS S30
4.00 ea
5
72006670
BALL VALV 1/2NPT 908
AISI 316
2.00 ea
5
72001453
NPL 1/2X1 908
AISI 316
2.00 ea
26006878
A ROTOR ZW 14X10X24F 139
A 351 Gr. CF8M - UNS J929
1.00 ea
FOR 7.2.2.-12 Rev. 0 (Bill of Materials)
Page 1 of 4
BILL OF MATERIALS
PUMP DESCRIPTION: ZW 14X10X24
Level
Part Number
Part Description
PROJECT:
Material
153200083
Quantity
4
13003288
SFT ZW 100X1168MT 305
A 434 Gr. 4140 Cl BC
1.00 ea
4
15006538
IMP ZW 14X10X24F 139
A 351 Gr. CF8M - UNS J929
1.00 ea
4
75001271
KEY SBE 28X16X233MT 301
A 576 Gr. 1045 - UNS G104
1.00 ea
4
69006341
SFT SLV ZW 100MT 310
A 276 Ty 316 - UNS S31600
1.00 ea
4
69006615
SFT SLV ZW 100MT 310
A 276 Ty 316 - UNS S31600
1.00 ea
4
20000919
ORNG 111X5MT 568
-
2.00 ea
26007024
A DE BRNG ZW S100
A 48 Cl. 35B
1.00 ea
4
11003256
BRNG HNG ZW 100 115
A 48 Cl. 35B
1.00 ea
4
68002353
BRNG BALL SKF 6314
1.00 ea
4
25003091
KIT DE BRNG GREASE ZW S100
1.00 ea
5
61000385
LIP SL 85X100X10MT
1.00 ea
5
61000409
LIP SL 65X85X10MT
1.00 ea
5
60009166
ORNG 150X2MT 568
-
1.00 ea
5
12001215
BRNG CVR ZW S100 115
A 48 Cl. 35B
1.00 ea
5
73004676
HEX BLT 16X35MT 897
SAE J429 Gr. 5
4.00 ea
5
73004527
HEX BLT 16X45MT 897
SAE J429 Gr. 5
4.00 ea
5
71000934
GREASE FIT 1/8 902
Carbon Steel
1.00 ea
5
73003115
HEX PLUG 1/8 NPT 354
A 105
1.00 ea
5
75001276
KEY SBE 18X11X99MT 301
A 576 Gr. 1045 - UNS G104
1.00 ea
5
71001917
VRNG SL 76MT 910
63005789
SL GD ZW S100 902
Carbon Steel
1.00 ea
26007025
A NDE BRNG ZW S100
A 48 Cl. 35B
1.00 ea
4
11003257
BRNG HNG ZW 100 115
A 48 Cl. 35B
1.00 ea
4
68002353
BRNG BALL SKF 6314
1.00 ea
4
25003092
KIT NDE BRNG GREASE ZW S100
1.00 ea
5
61000385
LIP SL 85X100X10MT
1.00 ea
5
60009166
ORNG 150X2MT 568
-
1.00 ea
5
12001215
BRNG CVR ZW S100 115
A 48 Cl. 35B
1.00 ea
5
73004676
HEX BLT 16X35MT 897
SAE J429 Gr. 5
4.00 ea
5
73004527
HEX BLT 16X45MT 897
SAE J429 Gr. 5
4.00 ea
5
74000460
LCKNUT N 70MT 902
Carbon Steel
1.00 ea
5
74000804
LCKNUT WSH W 70MT 902
Carbon Steel
1.00 ea
5
71000934
GREASE FIT 1/8 902
Carbon Steel
1.00 ea
5
73003115
HEX PLUG 1/8 NPT 354
A 105
1.00 ea
5
71001917
VRNG SL 76MT 910
63005789
SL GD ZW S100 902
Carbon Steel
1.00 ea
63005789
SL GD ZW S100 902
Carbon Steel
2.00 ea
3
4
3
4
2
8/21/2020
FOR 7.2.2.-12 Rev. 0 (Bill of Materials)
1.00 ea
1.00 ea
Page 2 of 4
BILL OF MATERIALS
PUMP DESCRIPTION: ZW 14X10X24
Level
Part Number
1
CUS 81012114
2
Part Description
PROJECT:
Material
BS SERVICES
153200083
Quantity
1.00 ea
78000302
NAMEPLT UL/FM
-
1.00 ea
25003879
KIT PMP ZW 14x10x24F
Carbon Steel
1.00 ea
2
73005374
HEX BLT 1 1/4X3 1/4 897
SAE J429 Gr. 5
4.00 ea
2
74000161
LCK SPRG WSH 1 1/4 902
Carbon Steel
4.00 ea
2
72012075
RED BSH 1 1/2X1/4NPT 902
Carbon Steel
1.00 ea
1
72012075
RED BSH 1 1/2X1/4NPT 902
Carbon Steel
1.00 ea
1
72006170
AIR RLS VALV 1 NPTF
A 48 Cl. 30B
1.00 ea
1
25003414
KIT AIR VALVE NPT CONNECTION
Carbon Steel
1.00 ea
2
72001454
NPL 1/2X1 1/2 902
Carbon Steel
1.00 ea
2
72003785
RED BSH 1X1/2 NPT 354
A 105
1.00 ea
72010615
PIPE BRTHR 1X6 908
AISI 316
1.00 ea
2
72001344
ELBW 1 BW 90DEG 908
AISI 316
2.00 ea
2
72004142
NPL 1X6NPT 310
A 276 Ty 316 - UNS S31600
1.00 ea
25004627
KIT PRESSURE GAUGE 1/4 NPT 3
A 403 Gr. WP316L - UNS S3
1.00 ea
2
79003052
MAN DUAL UNITS
2
72011244
BALL VALV 1/4TRD 517
A 182 Gr. F316L - UNS S31
1.00 ea
2
72011359
NPL 1/4X2NPT 313
A 312 Gr. TP316L - UNS S3
2.00 ea
2
72011360
ELBW 1/4 NPT 90DEG 908
AISI 316
1.00 ea
25004431
KIT COMPOUND GAUGE 1/4 NPT 9
AISI 316
1.00 ea
2
79004963
COMPOUND GAUGE
AISI 316
1.00 ea
2
72011244
BALL VALV 1/4TRD 517
A 182 Gr. F316L - UNS S31
1.00 ea
2
72011359
NPL 1/4X2NPT 313
A 312 Gr. TP316L - UNS S3
2.00 ea
2
72011360
ELBW 1/4 NPT 90DEG 908
AISI 316
1.00 ea
1
77009674
ICE CLARKE C18HO-UFAD68 687H
1.00 ea
1
25003878
KIT 24VDC DRY BATTERY BANK
1.00 ea
2
81012251
BATTERY 12V DRY
4.00 ea
2
66009378
BPLT FOR CLARKE BATTERY RACK
2
25003597
KIT 24V BATTERY CABLES
1.00 ea
25003594
KIT BATTERY CABLE 2/0 AWG
2.00 ea
4
79003408
CABLE 2/0 AWG
-
4.00 m
4
79000450
CONNECTOR LUG 3/0 AWG
-
2.00 ea
4
79003412
CONNECTOR TOP POST CLAMP
-
2.00 ea
25003595
KIT BATTERY CABLE 2/0 AWG
4
79003409
CABLE 2/0 AWG
-
4.00 m
4
79000450
CONNECTOR LUG 3/0 AWG
-
2.00 ea
4
79003411
CONNECTOR TOP POST CLAMP
-
2.00 ea
1
1
1
1
3
3
8/21/2020
FOR 7.2.2.-12 Rev. 0 (Bill of Materials)
1.00 ea
A 36
2.00 ea
2.00 ea
Page 3 of 4
BILL OF MATERIALS
PUMP DESCRIPTION: ZW 14X10X24
Level
Part Number
3
Part Description
PROJECT:
Material
153200083
Quantity
25003596
KIT BATTERY CABLE 2/0 AWG
4
79003409
CABLE 2/0 AWG
-
2.00 m
4
79003411
CONNECTOR TOP POST CLAMP
-
2.00 ea
4
79003412
CONNECTOR TOP POST CLAMP
-
2.00 ea
1
80005644
CTRL PNL TORNATECH
1
88005808
SA COOL LOOP INLET 1 1/4
Carbon Steel
1.00 ea
2
72003704
RED BSH 1 1/2X1 1/4NPT 902
Carbon Steel
1.00 ea
2
72005904
ELBW 1 1/4 NPT 90DEG 901
-
6.00 ea
2
72001374
FIT TEE 1 1/4NPT 902
Carbon Steel
1.00 ea
2
73003375
SQR PLUG 1 1/4NPT 354
A 105
1.00 ea
2
72010643
FLEX HOSE 1 1/4
SAE 304
1.00 ea
2
79000443
PIPE CLAMP 1 1/4
1
72011365
MAIN RLF VALV 8X8 FLG 126
A 536 Gr. 80-55-06
1.00 ea
1
81011936
WASTE CONE 8X14 126
A 536 Gr. 80-55-06
1.00 ea
1
79000402
CNCT CMPRN 2 AWG YA2C
2.00 ea
1
79000445
SLV TCTIL 0/2 AWG
1.00 m
1
79000468
CABLE 2 AWG
-
1.00 m
1
73001152
HEX BLT 3/8X1/2 319
A 193 Gr. B8M Cl. 1 - UNS
2.00 ea
1
80005630
LEAK SWITCH
1.00 ea
1
65004303
TANK 800GAL
1.00 ea
1
71005304
LEVEL INDICATOR 2 MALE NPT
1.00 ea
1
79000490
EMERGENCY VENT 4
2.00 ea
1
79000491
UPDRAFT VENT 2
2.00 ea
1
79000492
TANK FILL CAP 2
1.00 ea
1
72002488
BALL VALV 1NPT 908
AISI 316
2.00 ea
1
72006703
BALL VALV 3/4NPT 908
AISI 316
1.00 ea
1
72002180
NPL 1X5NPT 908
AISI 316
2.00 ea
1
72002173
FIT TEE 1NPT 908
AISI 316
1.00 ea
1
72006268
RED BSH 1 1/2X1NPT 908
AISI 316
1.00 ea
1
72002078
FIT TEE TRD 1 1/2NPT 908
AISI 316
1.00 ea
1
73003610
SQR PLUG 1 1/2NPT 412
A 182 Gr. F316 - UNS S316
1.00 ea
1
72002229
RED BSH 1 1/2X1/2NPT 908
1
72002152
RED BSH 2X1NPT 908
8/21/2020
FOR 7.2.2.-12 Rev. 0 (Bill of Materials)
2.00 ea
1.00 ea
6.00 ea
*AISI 316
1.00 ea
AISI 316
1.00 ea
Page 4 of 4
SECTION 3
THIS MATERIAL IS THE PROPERTY OF PAN AMERICAN ENERGY S.L. ARGENTINE BRANCH AND IT CANNOT BE CALCATED, PHOTOCOPIED,
REPRODUCED, COPIED OR USED UNDER ANY PURPOSE, EXCEPT WITH
PREVIOUS WRITTEN AUTHORIZATION FROM PAN AMERICAN ENERGY S.L. ARGENTINE BRANCH. THE PERSON RESPONSIBLE FOR INFRINGING AND NOT
COMPLYING WITH THE AFOREMENTIONED RIGHTS WILL BE LIABLE TO BE
SANCTIONED IN ACCORDANCE WITH THE LAWS THAT CORRESPOND BY RIGHT.
No
REFERENCES
WASTE CONE & BATERRY SHIPPED LOOSE
PRESSURE RELIEF VALVE SHIPPED LOOSE
DIESEL TANK SHIPPED LOOSE
CONTROL PANEL SHIPPED LOOSE
LISTED UL & APPROVED FM
DIMENSIONS IN (*) ARE SUBJECT TO CHANGE DUE TO SUPPLIER
DIMENSIONS ARE IN MILLIMETERS [INCHES]
NOTES
No
A
IFA
PRELIMINARY EMISSION
STATUS
DESCRIPTION
UNIT:
AC NO.
DATE
MA
DISCIPLINE:
JJG
JJG
DRAWN BY
CHECKED
APPROVED
PROJECT: 153200083
M
TITLE:
IRAM A3
CONTRACTOR DRG. NO:
---
SCALE:
1:30
CONTRACTOR PROJECT:
---
SHEET:
1 OF 1
SIZE:
GAP
05/12/20
REPLACE: ---
GENERAL ARRANGEMENT DRAWING
DRG.
NO.
---
A
2.2835
2.2756
5 3/8
[137]
B
0.7104
0.7087
2.5591
Ø 2.5581
B
3 15/16
[100]
SECTION B
ROTATION CW
VIEWED FROM COUPLING END
DETAIL A
1
25 19/32
[650]
18 29/32
[480]
53 5/32
[1350]
27 9/16
[700]
23 7/32
[590]
26 11/32
[669]
47 9/32
[1201]
20 15/16
[532]
18°
9°
PLAN 7311
Ø23
22.50°
Ø16 1/4
11.25°
Ø15 1/4
17 5/16
[440]
3
Ø12 3/4
2
15 3/4
[400] 1 3/8
15 3/4
[400]
[35]
A
26 25/32
[680]
DISCHARGE
FLANGE ∅10
ANSI #300 RF
13 3/16
[335]
4
5 7/8
[150]
31/32
[25]
SUCTION
FLANGE ∅14
ANSI #300 RF
16 17/32
[420]
19 7/8
[505]
4
5 7/8
[150]
(4X) Ø 1.38 [35]
THRU HOLES
24 13/16
[630]
31 1/2
[800] 38 3/16
[970]
1.- ALL DIMENSIONS ARE IN INCHES, DIMENSIONS BETWEEN [ ] ARE IN MM. AND SHOULD BE USE FOR REFERENCE ONLY.
2.- FOR INFORMATIONAL PURPOSE ONLY, DO NOT USE FOR PRODUCTION
(16X) Ø1 1/8
THRU HOLES
Ø20 1/4
15 3/4
[400]
25 19/32
[650]
29 17/32
[750]
Ø17 1/2
(20X) Ø1 1/4
THRU HOLES
SUCTION FLANGE ∅14
ANSI #300 RF
DISCHARGE FLANGE ∅10
ANSI #300 RF
DIESEL ENGINE FIRE PUMP CONTROLLER
ENGINE
REFERENCES
No
No
NOTES
SECTION 4
Operation and Maintenance
Instructions Manual
C18 MODELS
ELECTRONIC ENGINES
FOR
FIRE PUMP APPLICATIONS
This manual covers Caterpillar Engines
Prepared by Clarke
for fire pump service
Clarke Fire Protection Products, Inc.
100 Progress Place
Cincinnati, OH 45246
U.S.A.
TELE: +1.513.475.3473
FAX: +1.513.771.0726
Clarke UK, Ltd.
Unit 1, Grange Works
Lomond Road
Coatbridge
ML5 2NN
United Kingdom
TELE: +44(0)1236 429946
FAX: +44(0)1236 427274
www.clarkefire.com
C137833
03/20
RevE
CONTENTS
SUBJECT
PAGE
1.0 INTRODUCTION
4
1.1 IDENTIFICATION/NAMEPLATE
4
1.2 SAFETY/CAUTION/WARNINGS
5
1.3 PRECAUTIONS FOR WELDING
9
2.0 INSTALLATION/OPERATION
10
2.1 TYPICAL INSTALLATION
10
2.2 ENGINE STORAGE
10
2.2.1 Storage Less than 1 year
10
2.2.2 Extended Storage Maintenance Procedure
10
2.2.3 Coolant System
11
2.2.4 Removal from Storage
11
2.3 INSTALLATION INSTRUCTIONS
12
2.4 SPECIFIC FLYWHEEL COUPLING ALIGNMENT INSTRUCTIONS
13
2.4.1 Driveshaft
13
2.5 WEEKLY TEST
16
2.6 STARTING/STOPPING THE ENGINE
16
2.6.1 To Start Engine
16
2.6.1.1 Start Engine for Test Purposes (“Soft Start”)
3.0
16
2.6.2 To Stop Engine
17
2.6.3 Describing Engine Gauge Panel
18
2.6.3.1 ECM Selector Switch and Primary/Alternate Electronic Control Modules (ECM’s)
18
2.6.3.2 Dual ECM Automatic Switching
18
2.6.3.3 Programming ECM with Automatic Switching Device
19
2.6.3.4 Using Power View Gauge
19
ENGINE SYSTEMS
29
3.1 FUEL SYSTEM
29
3.1.1 Diesel Fuel Specification
29
3.1.2 Bleeding the Fuel System
30
3.1.2.1 C18 Engine Series after Filter Change
30
3.1.2.2 C18 Engine Series After Engine was Run Out of Fuel
31
3.1.3 Changing Fuel Filters
31
3.1.3.1 C18 Engine Series
31
3.1.4 Fuel Tanks
32
3.2 AIR/EXHAUST SYSTEM
32
3.2.1 Ambient Conditions
32
3.2.2 Ventilation
32
3.2.3 Standard Air Filter
32
3.2.4 Crankcase Ventilation
33
1
3.2.5 Exhaust System
34
3.3 LUBRICATION SYSTEM
34
3.3.1 Checking Sump Oil
34
3.3.2 Changing Engine Oil
35
3.3.3 Changing Oil Filter Cartridge
35
3.3.4 Oil Specification
35
3.3.5 Oil Capacities
35
3.4 COOLING SYSTEM
35
3.4.1 Intended Engine Operating Temperature
35
3.4.2 Engine Coolant
35
3.4.3 Water
36
3.4.4 Coolant Capacities
36
3.4.5 Coolant Inhibitors
36
3.4.6 Procedure for Filling Engine
37
3.4.7 Providing Adequate Raw Water Supply to the Engine Heat Exchanger
37
3.4.7.1 Raw Water Supply
37
3.4.7.2 Cooling Loop
37
3.4.7.3 Setting Raw Water Flow Rate
39
3.4.7.4 Raw Water Outlet
39
3.4.7.5 Raw Water Quality Strainers and Deterioration of Heat Exchanger (CAC)
39
3.4.7.6 Backflow Preventers
40
3.4.7.7 Raw Water Outlet Temperature
40
3.4.8 Flow Paths of Engine Cooling System
40
3.4.9 Important Service Notice
42
3.4.9.1 Water Pump Cavitation
42
3.5 ELECTRICAL SYSTEM
42
3.5.1 Wiring Diagrams
42
3.5.2 Checking Drive Belt Tension and Adjustment
42
3.5.3 Engine Overspeed
42
3.5.4 Field Simulation of Pump Controller Alarms
43
3.5.5 Battery Requirements
43
3.6 ENGINE SPEED ADJUSTMENT
4.0
43
MAINTENANCE SCHEDULE
44
4.1 ROUTINE MAINTENANCE
5.0
44
TROUBLE SHOOTING
44
5.1 DIAGNOSTIC TROUBLE CODES
6.0
7.0
45
PARTS INFORMATION
46
6.1 SPARE PARTS
46
6.2 ENGINE MAINTENANCE PARTS LIST
46
OWNER ASSISTANCE
46
2
8.0
9.0
WARRANTY
46
8.1 GENERAL WARRANTY STATEMENT
46
8.2 CLARKE WARRANTY
47
8.3 CATERPILLAR WARRANTY
47
INSTALLATION & OPERATION DATA
47
10.0 WIRING DIAGRAMS
47
11.0 PARTS ILLUSTRATION & DRAWINGS
47
12.0 KEYWORD INDEX
48
13.0 APPENDIX “A” C18 Models Parts Matrix
49
14.0 APPENDIX “B” Caterpillar Limited Warranty
50
Check factory availability for a manual in one of the following languages:
Spanish
German
French
Italian
NOTE
The information contained in this book is intended to assist operating personnel by providing information
on the characteristics of the purchased equipment. It does not relieve the user of their responsibility of
using accepted practices in the installation, operation, and maintenance of the equipment.
NOTE: CLARKE FPPG Reserves the right to update the contents of this publication without notice.
3
1.0 INTRODUCTION
MODEL NUMBERING & IDENTIFICATION
The following paragraphs summarize the “Scope of
Supply” of the Engine:
There are two identification tags attached to each
engine. Clarke Identification Plate: Engine Model,
Serial Number, Rating and Date of Manufacture are
shown on this identification plate. The C18 Series
identification plate is mounted on the back of the left
rear engine mounting foot. (See Figure #1)

The CLARKE Engine supplied has been
designed for the sole purpose of driving a
stationary Emergency Fire Pump. It must not
be used for any other purpose.

Shall not be subjected to Horsepower
requirements greater than the certified
nameplate rating (for UL/cUL/FM only).

Engines must be sized to cover fully the
maximum power absorbed by any particular
driven equipment together with a safety
factor on no less than 10%. (For Non-listed
only).

De-rates for elevation ambient and
temperature need to be considered for
maximum pump power.

Fuel delivery settings are factory set and
must not be tampered with or adjusted.
Minor RPM adjustments to meet pump
requirements are permissible.

The engine shall be installed and maintained
in accordance with the guidelines stated in
this manual.

Periodic running checks to ensure
functionality should be kept to a maximum of
½ hour per week.
Clarke Identification Plates
USA Listed/Approved
Figure #1
Clarke model number reflects the base engine type,
engine displacement, cooling system, environmental
suitability, approval listing, engine speed, and a
power rating code.
Example: C18H0-UFAC28





1.1 IDENTIFICATION/NAMEPLATE

Throughout this manual, the terms “Engine”
and “Machine” are used.

The term “Engine” refers solely to the diesel
engine driver as supplied by CLARKE.



The term “Machine” refers to any piece of
equipment with which the engine might
interface.

C = Caterpillar base engine
18 = base engine displacement (18.1 liter)
H = Heat Exchanger cooled (R = Radiator)
0 = Non-Hazardous Location
UF = Underwriters Laboratories Listed/
Factory Mutual Approved, (NL = NonListed)
A = Manufacture Location (United States)
C = Tier 2, D = Tier 3, A = NonEmissionized
28 = Power Rating Code
Caterpillar Identification Label: The second
identification tag contains the Caterpillar Feature
Code and Serial Number. On the C18 Series, the
Caterpillar identification tag is located on the lefthand side of the engine forward of the air intake.
This manual provides all the information necessary to
operate your newly acquired engine safely and
efficiently, and perform routine servicing correctly.
Please read it carefully.
4
1.2 SAFETY/CAUTION/WARNINGS
ATTENTION:
This engine has components and
fluids that reach very high operating temperatures
and is provided with moving pulleys and belts.
Approach with caution. It is the responsibility of the
builder of the machine, using a Clarke engine, to
optimize the application in terms of maximum end
user safety.
BASIC RULES
The following recommendations are given to reduce
the risk to persons and property when an engine is in
service or out of service.
Figure #3
When Clarke furnishes the base (or module) for the
engine and pump set, the combined weight of the
engine and base (or module) will be indicated on the
unit. Caution, when lifting, lift point should always
be over the equipment Center of Gravity.
Engines must not be used for applications other than
those declared under “Scope of Supply”.
Incorrect handling, modifications, and use of nonoriginal parts may affect safety. When lifting the
engine, take care to use suitable equipment to be
applied to the points specially provided as shown on
the appropriate Engine Installation Drawing. Engine
weights are shown in figure #4.
Note: The engine produces a noise level exceeding
70 dB(a). When performing the weekly functional
test, it is recommended that hearing protection be
worn by operating personnel.
Figure #2 shows the typical lifting arrangement of a
bare engine. Note the lifting points on the engine are
for lifting the engine only. Caution, when lifting, lift
point should always be over the equipment Center of
Gravity.
CLARKE UK provides the machine manufacturer
with a Declaration of Incorporation”
for the Engine, when required, a copy of which is
enclosed in the manual. This document clearly states
the machine manufacturers’ duties and
responsibilities with respect to health and safety.
Refer to Figure #5.
Figure #2
Figure #3 shows the typical lifting arrangement of a
base mounted engine and pump set when the base (or
module) is furnished with lifting holes.
5
ENGINE MODEL
WEIGHT lbs. (kg)
C18H0-UFAC10
4100
(1860)
4100
(1860)
4100
(1860)
4100
(1860)
4100
(1860)
4100
(1860)
4100
(1860)
4100
(1860)
4100
(1860)
4100
(1860)
4100
(1860)
4100
(1860)
4100
(1860)
4100
(1860)
4100
(1860)
4100
(1860)
4100
(1860)
4100
(1860)
C18H0-UFAC18
C18H0-UFAC20
C18H0-UFAC28
C18H0-UFAD10
C18H0-UFAD18
C18H0-UFAD20
C18H0-UFAD28
C18H0-UFAD30
C18H0-UFAD38
C18H0-UFAD40
C18H0-UFAD48
C18H0-UFAD50
C18H0-UFAD58
C18H0-UFAD68
C18H0-UFAD70
*C18H0-UFAA78
C18H0-UFAD78
Figure #4
* Non-Emissionized
6
Figure #5
7
WHAT TO DO IN AN EMERGENCY
CAUSTIC BURNS
Any user of the Engine who follows the instructions set
out in this manual, and complies with the instructions
on the labels affixed to the engine are working in safe
conditions.
1) Caustic burns to the skin are caused by acid
escaping from the batteries:
 remove the clothes
 wash with running water, being
careful not to affect injury-free areas
2) Caustic burns to the eyes are caused by battery
acid, lubricating oil, and diesel fuel.
 Wash the eye with running water for at
least 20 minutes, keeping the eyelids
open so that the water runs over the
eyeball and moving the eye in all
directions.
If operating mistakes cause an accident, call for help
immediately from the EMERGENCY SERVICES.
In the event of an emergency, and while awaiting the
arrival of the EMERGENCY SERVICES, the
following general advice is given for the provision of
first aid.
FIRE
ELECTROCUTION
Put out the fire using extinguishers recommended by
the manufacturer of the machine or the installation.
Electrocution can be caused by:
1) The engine’s electrical system (24VDC)
BURNS
1) Extinguish the flames on the clothing of the
burn victim by means of:
 drenching with water
 use of powder extinguisher, making
sure not to direct the jets onto the face
 blankets or rolling the victim on the
ground
2) Do not pull off strips of clothing that are
sticking to the skin.
3) In the case of scalding with liquids, remove the
soaked clothing quickly but carefully.
4) Cover the burn with a special anti-burn packet
or with a sterile bandage.
2) The coolant pre-heating system 120/240 Volt
AC (if supplied).
In the first case, the low voltage does not involve high
current flows through the human body; however, if
there is a short circuit, caused by a metal tool, sparks
and burns may occur.
In the second case, the high voltage causes strong
currents, which can be dangerous.
If this happens, break the current by operating the
switch before touching the injured person.
If this is not possible, bear in mind that any other
attempt is highly dangerous for the person assisting.
Any attempt to help the victim must be carried out
using means to insulate the rescuer from the electrical
current.
CARBON MONOXIDE POISONING (CO)
Carbon monoxide contained in engine exhaust gases is
odorless and dangerous because it is poisonous and
with air, it forms an explosive mixture.
WOUNDS AND FRACTURES
The wide range of possible injuries and the specific
nature of the help needed means that the medical
services must be called.
If the person is bleeding, compress the wound
externally until help arrives.
In the case of fracture, do not move the part of the
body affected by the fracture. When moving an injured
person, permission from that person must be received
before you can help him. Unless the injury is life
threatening, move the injured person with extreme care
and then only if strictly necessary.
Carbon monoxide is very dangerous in enclosed
premises because it can reach a critical concentration
in a short time.
When attending a person suffering from CO poisoning
in enclosed premises, ventilate the premises
immediately to reduce the gas concentration.
When accessing the premises, the person providing the
aid must hold his breath, not light flames, turn on lights
or activate electric bells or telephones to avoid
explosions.
Take the victim to a ventilated area or into the open air,
placing him on his side if he is unconscious.
WARNING LABELS
Warning labels, in picture form, are applied to the
engine. Their meanings are given below.
8
Important Note: Labels that show an exclamation
mark indicate that there is a possibility of danger.
Jacket Water Heater Voltage
Heat Exchanger Maximum Working Pressure
Coolant Mixture
Air Filter Installation
Lifting Point
1.3 PRECAUTIONS FOR WELDING
IMPORTANT:
ALWAYS disconnect electronic
Control Module (ECM) connectors before welding.
High currents or electrostatic discharge in electronic
components, from welding, may cause permanent
damage. Connect the welder ground close to the
welding point and be sure ECM or other electronic
components are not in ground path.
Automatic Start
Rotating Parts
9
2.0 INSTALLATION/OPERATION
If an engine is not used, oil can run off the following
parts that normally receive lubrication: cylinder walls,
piston rings, main bearings, connecting rod bearings,
crankshaft and gears.
2.1 TYPICAL INSTALLATION
A typical Fire Pump installation is shown in Figure #6.
This lack of lubricant allows corrosion to begin to
appear on the metal. This condition is worse in areas of
high humidity.
1. Pump/Engine set
2. Main Pump Controller
3. Pump discharge
4. Air louver
5. Entrance door with air louver
6. Exhaust silencer
7. Exhaust system supports
8. Exhaust outlet pipe
9. Concrete base
10. Exhaust flexible connection joint/pipe
When the engine is started again, metal to metal
contact will cause wear before the surfaces receive oil.
To minimize this wear, use the starter to turn the
engine with the throttle in the FUEL OFF position.
When oil pressure is shown on the pressure gauge, start
the engine.
1. Clean the engine of any dirt, rust, grease, and
oil. Inspect the exterior. Paint areas that
contain paint damage with a good quality
paint.
2. Remove dirt from the air cleaners. Check all
seals, gaskets, and the filter element for
damage.
3. Apply lubricant to all points in this Operation
and Maintenance Manual, "Maintenance
Interval Schedule".
4. Drain the crankcase oil. Replace the crankcase
oil and change the oil filters. For the proper
procedure, refer to this Operation and
Maintenance Manual.
5. If the engine is equipped with an air starting
motor, fill the reservoir with the following
mixture: 50 percent volatile corrosion inhibitor
oil (VCI oil) and 50 percent engine oil.
6. Add VCI oil to the crankcase oil. The volume
of VCI oil in the crankcase oil should be 3 to 4
percent.
Figure #6
Typical Installation
2.2 ENGINE STORAGE
2.2.1 Storage less than 1 year
Storing engines requires special attention. Clarke
engines, as prepared for shipment, may be stored for a
minimum of one year. During this period, they should
be stored indoors in a dry environment. Protective
coverings are recommended provided they are
arranged to allow for air circulation. The stored engine
should be inspected periodically for obvious conditions
such as standing water, part theft, excess dirt buildup
or any other condition that may be detrimental to the
engine or components.
Any such conditions found must be corrected
immediately.
Note: If the engine crankcase is full, drain
enough engine oil so the mixture can be added.
7. Remove the air filter elements. Turn the engine
at cranking speed with the throttle control in
FUEL OFF position. Use a sprayer to add a
mixture of 50 percent VCI oil and 50 percent
engine oil into the air inlet or turbocharger
inlet.
Note: The mixture of VCI oil can be added to
the inlet by removing the plug for checking
turbocharger boost pressure. The minimum
application rate for the VCI oil mixture is 5.5
mL per L (3 oz per 1000 cu in) of engine
displacement.
2.2.2 Long-Term Storage
Note: It is recommended that a Clarke Service Dealer
perform the steps outlined in this section.
10
8. Use a sprayer to apply a mixture of 50 percent
VCI oil and 50 percent crankcase oil into the
exhaust openings. The minimum application
rate for the oil mixture is 5.5 mL per L (3 oz
per 1000 cu in) of engine displacement. Seal
the exhaust pipe and seal any drain holes in the
muffler.
9. Remove the fuel from the secondary fuel filter
housing. Alternately, empty and reinstall the
spin-on fuel filter element in order to remove
any dirt and water. Drain any sleeve metering
fuel pump.
periodically charge the batteries while the
batteries are in storage.
If the batteries are not removed, wash the tops
of the batteries until the tops are clean. Apply
an electrical charge to the batteries in order to
obtain a specific gravity of 1.225.
Disconnect the battery terminals. Place a
plastic cover over the batteries.
Note: For additional information, refer to
Special Instruction, SEHS7633, "Battery Test
Procedure".
Clean the primary fuel filter. Fill with
calibration fluid or kerosene. Install the
primary fuel filter and operate the priming
pump. This procedure will send clean oil to the
secondary filter and the engine.
14. Loosen all belts.
15. Place a waterproof cover over the engine.
Ensure that the engine cover is secure. The
cover should be loose enough to allow air to
circulate around the engine in order to prevent
damage from condensation.
16. Attach a tag with the storage date to the
engine.
17. Remove the waterproof cover at 2 month or 3
month intervals in order to check the engine
for corrosion. If the engine has signs of
corrosion, repeat the protection procedure.
10. Remove the fuel nozzles or spark plugs. Apply
30 mL (1 oz) of the mixture of oils (50 percent
VCI oil and 50 percent engine oil) into each
cylinder.
Use a bar or a turning tool in order to turn over
the engine slowly. This procedure puts the oil
on the cylinder walls. Install all fuel nozzles or
spark plugs and tighten to the correct torque.
2.2.3 Coolant System
11. Spray a thin amount of a mixture of 50 percent
VCI oil and 50 percent engine oil onto the
following components: flywheel, ring gear
teeth and starter pinion. Install the covers in
order to prevent evaporation of the vapors
from the VCI oil.
12. Apply a heavy amount of Cat Multipurpose
Grease (MPGM) to all outside parts that move,
such as rod threads, ball joints, linkage.
Completely fill the cooling system before storage. (It
is common for Clarke to ship the engine pre-filled with
coolant.)
Refer to the Operation and Maintenance Manual,
"Fluid Recommendations" (SEBU8598) for more
information about coolants.
2.2.4 Removal from Storage
Note: Install all covers. Ensure that tape has
been installed over all openings, air inlets,
exhaust openings, the flywheel housing, the
crankcase breathers, the dipstick tubes.
1. Remove all outside protective covers.
2. Change the oil and filters.
3. Check the condition of the fan and alternator
belts. Replace the belts, if necessary. Refer to
this Operation and Maintenance Manual,
"Belts - Inspect/Adjust/Replace" for the correct
procedure.
4. Replace the fuel filter elements.
5. Remove the plastic covers from the air cleaner
elements.
6. Use a bar or a turning tool in order to turn the
engine in the normal direction of rotation. The
procedure ensures that no hydraulic locks or
resistance exist.
Ensure that all covers are airtight and
weatherproof. Use a waterproof weather
resistant tape such as Kendall No. 231 or an
equivalent. Do not use duct tape. Duct tape
will only seal for a short time.
13. Under most conditions, removing the batteries
is the best procedure. As an alternative, place
the batteries in storage. As needed,
11
7. Before starting the engine, remove the valve
cover or covers. Put a large amount of engine
oil on the camshaft, cam followers, and valve
mechanism in order to prevent damage to the
mechanism.
8. Pressure-lubricate the engine before starting
the engine. Pressure lubricating the engine
ensures immediate lubrication and prevents
damage to the engine during the first few
minutes of engine operation. If the engine is
not equipped with a prelube pump, contact
your Cat dealer for information about
lubrication of the engine before starting the
engine.
9. Check the condition of all rubber hoses.
Replace any worn hoses. Replace any damaged
hoses.
10. Before start-up, test the cooling system for a 3
percent to a 6 percent concentration of coolant
conditioner. Add liquid coolant conditioner or
a coolant conditioner element, if equipped.
Operation Data Sheets. If there is any doubt about an
installation, contact should be made with Clarke
Customer Support giving exact details of the problem.
All installations should be clean, free of any debris and
dry. Care should be taken to ensure that there is easy
access to the engine for maintenance and repair. The
safety of personnel who may be around the engine,
when it is running, is of paramount importance when
designing the installation layout.
1) Secure pump set to foundation and complete
installation in accordance with pump
manufacturer’s instructions. Perform engineto-pump coupling alignment.
Lubricate
driveshaft universal joints with NLGI grade #1
or #2 grease at the (3) Zerk fittings. (Refer to
section 2.4 for specific alignment instructions).
2) Install the heat exchanger discharge pipe. The
discharge pipe should be no smaller than the
outlet connection on the heat exchanger.
Discharge water piping should be installed in
accordance with applicable codes. All
plumbing connecting to the heat exchanger
must be secured to minimize movement by the
engine. Cooling loop water pressure to the
heat exchanger must not exceed the limit that
is stated on the heat exchanger supplied with
the engine.
3) Install all engine cooling system draincocks
and plugs. Close all drain cocks.
Test the coolant mixture for proper nitrite
level. If necessary, adjust the coolant mixture.
Prime the engine with clean diesel fuel before
starting.
11. Ensure that the cooling system is clean. Ensure
that the system is full. Ensure that the system
has the correct amount of supplemental
cooling system conditioner.
12. On the first day of operation, check the entire
engine several times for leaks and correct
operation.
13. If the engine was removed from storage in
which temperatures of less than -12°C (10°F)
were encountered, refer to Service Manual,
SEBU5898, "Cold Weather Recommendations
Operation and Maintenance".
Qty
1
1
1
Description
1/8”
draincock
1/4”
draincock
Electrode
plug
Location
Coolant heater
inlet tube
Water pump
inlet tube
Bottom of heat
exchanger
Engine
Model
C18
C18
C18
4) Fill engine cooling system with premixed 50%
water / 50% coolant solution. Use only
coolants meeting ASTM-D6210 specifications
for heavy-duty diesel engines. Never use lightduty or automotive coolants in the engine that
are stated as ASTM-D3306 only. (Refer to
Section 3.4.3 of this manual for cooling
system capacity.) Fill expansion tank per
figure #18, Section 3.4.5 of Instruction
Manual.
5) Engine is shipped with oil installed. For
make-up oil specifications refer to section 3.3
Lubrication System.
2.3 INSTALLATION INSTRUCTIONS
The correct installation of the engine is very important
to achieving optimum performance and extended
engine life.
In this respect, the engine has certain installation
requirements, which are critical to how it performs.
These requirements are generally associated with the
cooling, exhaust, induction air, and fuel systems.
This section of the manual should be read in
conjunction with the relevant Installation and
12
6) Connect fuel supply and return line to fuel
supply tank plumbing. Reference the Fuel
System section of the Installation and
Operation Data in (See clarkefire.com), for
piping size, maximum allowable fuel pump
suction, and maximum allowable fuel head
requirements. Fill supply tank with #2 diesel
fuel (ASTM D-975) or BS 2869 Class A2
“Red” diesel fuel, bleed supply system of air
and check for leaks.
CAUTION: Biodiesel fuel is not
recommended for stand-by equipment that
can have minimal fuel consumption (such as
standby generators, fire protection, etc.).
For standby applications, use only
petroleum based diesel fuel with Caterpillar
approved fuel conditioners/ additives. For
fuel conditioners/additives, check with your
local CAT dealer or Clarke. Fuel supply
level must meet applicable code requirements.
Do not use a copper based or galvanized
material for any component of a diesel fuel
system. The fuel will chemically react with the
zinc resulting in clogged fuel filters and
injector systems.
7) Remove protective covering on air filter
element.
8) Connect jacket water heater (if supplied) to
AC power source. For C18 Series, the
electrical supply requirements are indicated on
the connection box. Connect to the heater
directly to the junction box at the end of the
heater only. Supply wiring should never be
routed through the engine gauge panel.
Severe damage to critical engine control
components could result. Energize heater only
after step #4 is completed.
9) Connect exhaust system to flexible connection
on the engine. The exhaust system plumbing
must be supported by the building structure
and not the engine. The exhaust flexible
connection is provided only for the purpose of
thermal expansion and vibration isolation, not
for misalignment or directional change.
10) Make electrical DC connections between the
engine gauge panel terminal strip (if supplied)
and the controller per the controller
manufacturer’s instructions.
11) Fill batteries with electrolyte per battery
manufacturer’s instructions. Connect cables
between engine and batteries only after
electrolyte is installed. Refer to the wiring
diagram inside the engine gauge panel cover
(if supplied), or appropriate wiring diagram
(see Page 5), for correct positive and negative
connections. Connect negative cables directly
to the engine block. Connect each positive
cable to the large outer post of the manual
starting contactors.
12) Note: Clarke Operation and Maintenance
Instructions Manual, C137833, is located
inside the engine gauge panel.
13) Note: During commissioning of the engine,
the final speed setting must be performed on
both the Primary and Alternate ECM’s. Refer
to section 3.6 Speed Adjustment.
14) IMPORTANT! To obtain prompt Warranty
Service and to comply with Emissions
Regulations, this engine must be registered to
the final installation name and address. To
register this engine, go to
www.clarkefire.com and select Warranty
Registration.
2.4 SPECIFIC FLYWHEEL COUPLING
ALIGNMENT INSTRUCTIONS
2.4.1 Driveshaft
To check the alignment of the pump shaft and engine
crankshaft centerlines for proper Parallel Offset and
Angular tolerance, the drive shaft must be installed
between the flywheel and the flanged hub on the pump
shaft.
Before beginning the alignment checks and making
any necessary corrections, install the driveshaft and retorque all driveshaft connection bolts to the values
given in the following tables.
13
MODELS
DRIVE
SHAFT
BOLT
SIZE
/GRADE
* - 2100 rpm only
** - 1900 rpm only
TIGHTENING
TORQUE
ft-lbs
(N-m)
Note 1 – It is recommended that a medium strength
threadlocker (Loctite 243–blue) be used in the
assembly and of all hardware. This may be purchased
as part number C126758, 50ml bottle.
C18H0UFAD10
C18H0UFAD18
Note 2 – 4 of the hi-tensile bolts and/or nuts, that are
used to connect the driveshaft to the drive disc and that
connect the driveshaft to the pump companion flange,
will require a “crow’s foot” wrench attached to a
standard torque wrench to apply the required tightening
torque. A standard socket will not work due to
proximity of the bolts and/or nuts with the driveshaft
yoke. The tightening torque values listed for these
bolts and/or nuts have been corrected for using a
“crow’s foot” adapter which extends the standard
torque wrench’s length.
C18H0UFAD20
C18H0UFAD28
C18H0UFAD30
SC2160A
M16,
Class 10.9
(Metric)
(HiTensile)
100 - 105
(135 - 142)
(see note #2)
C18H0UFAD38
C18H0UFAD40
Note 3 – For the high torque required for these nuts, it
is recommended that a boxed-end crows foot be used.
C18H0UFAD48
The following steps describe the proper way to check
alignment. A small pocket scale or ruler with
millimeter markings is recommended to make all
measurements.
C18H0UFAD50
C18H0UFAD70*
MODELS
DRIVE
SHAFT
BOLT
SIZE
/GRADE
Before removing the drive shaft guard, disconnect the
negative battery cable from both batteries.
TIGHTENING
TORQUE
ft-lbs
(N-m)
A) To check the Horizontal Parallel Offset, the
driveshaft must be in the proper orientation.
1. Rotate the shaft so the reference “AB” on the
flywheel adapter disc or the circumference of
the drive shaft flange (against the flywheel
adapter disc) is in the 12 o’clock position
shown on Figure #7a.
2. Measure from the face of the flywheel adapter
disc to point E. (Point E is on the bearing bore
as shown in Figure #7a). This measurement
must be:
C18H0UFAD58
C18H0UFAD68
C18H0UFAD70**
C18H0UFAA78
C18H0UFAD78
C18H0UFAC10
SC2390A
M16,
Class 10.9
(Metric)
(HiTensile)
210 - 220
(285 - 298)
(see note #2,
#3)
Measurement
123.5 + 1.5mm
142.5 + 1.5mm
C18H0UFAC18
C18H0UFAC20
C18H0UFAC28
14
Driveshaft
SC2160A
SC2390A
Figure #7a
B) With the driveshaft in the same orientation as the
previous step (Step A), check the Horizontal
Angular alignment of the shafts.
1. Measure from the mating surface of the
companion hub to point G shown on figure
#7b. (Point G is the furthermost point on the
bearing bore). This measurement must be
equal to the measurement at point E + 0.5 mm.
Figure #7c
D) With the driveshaft in the same orientation as the
previous step (Step C), check the Vertical
alignment of the shafts.
1. Measure from the mating surface of the pump
companion hub of the drive shaft to point J as
shown in figure #7d. (Point J is the same as
point G, with the driveshaft rotated 90o). This
measurement must be equal to the
measurement at point H + 1 mm.
Re-install all guards and grease fittings before
reconnecting the battery cables.
Figure #7b
C) To check the Vertical Parallel Offset, the
driveshaft must be re-orientated.
1. Rotate the shaft 90○ so the reference “CD” on
the flywheel adapter disc or the circumference
of the drive shaft flange (against the flywheel)
is in the position shown on Figure#7c.
2. Measure from the face of the flywheel adapter
disc to point H. (Point H is the furthermost
point on the bearing bore diameter). The
measurement must be:
Measurement
126.5 + 1mm.
145.5 + 1.5mm.
Figure#7d
DRIVESHAFT MAINTENANCE
1. To service the driveshaft, disconnect the
negative battery cables, remove the top of
guard and set aside.
2. Rotate engine shaft manually so the u-joint
grease fittings are accessible.
3. Using a hand-held grease gun with N.L.G.I.
grade 1 or 2 grease position on grease fitting.
Driveshaft
SC2160A
SC2390A
15
Pump with grease until grease is visible at all
four cap seals.
4. Verify all driveshaft connecting bolts remain
tight. Re-torque per 2.4.1 if necessary.
5. Reinstall top of guard and connect negative
battery cables.
MANUAL CRANK #1, until engine starts, or release
after 15 seconds. If unit fails to start, wait for 15
seconds, use MANUAL CRANK #2 and repeat step.
If RAW COOLING WATER is not flowing or
engine COOLANT
TEMPERATURE is too HIGH, open cooling system
manual by-pass valves.
2.5 WEEKLY TEST
Note: On C18 Engines you can also start engines using
manual starting contactors.
An experienced operator should be present during the
weekly test.
IMPORTANT: Main pump controller selector should
be in the OFF position when starting from engine
gauge panel. Be sure to return selector on main pump
controller and engine gauge panel to AUTOMATIC
after completing manual run.
NOTE: This engine is designed to operate at rated load
conditions. For testing purposes the engine can be run
at lower load (lower flow) conditions. Running times
in any one period should not exceed a maximum of 30
minutes. Before starting the engine make sure of the
following:
1) The operator has free access to stop the engine
in an emergency.
2) The plant room ventilation ducts are open and
the engine has good access for air.
3) All the guards are in position and, if not, for
whatever reason, any rotating parts will be free
and clear without restriction.
4) Battery covers are in place and there is nothing
on top of or touching the engine, which is not
part of the original supply specification.
5) The raw water supply for cooling is available
without restriction. Typically, restriction
occurs from a plugged cooling loop strainer.
2.6.1.1 Start Engine for Test Purposes (“Soft Start”)
During installation of the sprinkler system or initial
commissioning, it may be desirable to start the engine
at a reduced speed. Reducing the speed reduces the
pressure of the pump discharge. This allows leak
detection to be performed at reduced system pressure
and reduces the likelihood of water hammer at start.
The process is simple with a mechanical engine as it
has a mechanical linkage that can be removed. No
provision exists on most electronic engines.
C18 models from Clarke are equipped with a “Soft
Start” feature to allow operation at a reduced speed.
To use the feature, the engine should be started
manually from the engine gauge panel. To use the
feature:
1) Switch the main fire pump controller to the
OFF position.
2) Switch the MODE SELECTOR to
MANUAL RUN. (Refer to Figure #8).
3) Open the engine gauge panel and locate the
“Soft Start” switch. It is a momentary toggle
switch located in the upper part of the panel
interior. (See Figure #9B).
4) With your left hand, pull the toggle switch
towards you and maintain that position. Then
lift and hold the MANUAL CRANK #1 on
the front of the engine gauge panel with your
right hand. Release it when the engine starts.
5) The engine will run at 1100 rpm until the “Soft
Start” toggle is released. Once the toggle is
released, the engine will increase speed at the
rate of 10 rpms per second until it reaches
rated speed. The “Soft Start” toggle can be
activated again and the engine will
immediately return to 1100 rpm.
When engine is running make sure that the coolant
temperature, oil pressure and raw cooling water flow
are within the limits specified on the relevant
Installation & Operation Data Sheet (see Page 5).
If the coolant temperature is excessive, check:
a) Cooling loop strainers
b) Proper functioning of thermostat
c) Condition of heat exchanger tube bundle
2.6 STARTING/STOPPING THE ENGINE
2.6.1 To Start Engine
Use main pump controller for starting. Follow
instructions provided by controller manufacturer.
On UL/FM engines, use main pump controller for
starting and stopping the engine. Should the main
pump controller become inoperable, the engine can be
manually started and stopped from the engine gauge
panel. For manual starting and stopping of an engine
with a gauge panel: Position MODE SELECTOR to
MANUAL RUN. (Refer to Figure #8). Lift and hold
16
2.6.2
To Stop Engine
Note: This is NOT the switch to use during cyclecrank testing. This switch will allow the engine to
briefly start, before stopping the engine.
IMPORTANT: DO NOT leave the MODE
SELECTOR switch in the MANUAL RUN position
during AUTOMATIC operation. (The controller will
be unable to stop the engine and DAMAGE MAY
RESULT).
If engine is started from main pump controller use
main pump controller to stop the engine.
If engine is started from engine gauge panel: Lift and
hold MANUAL STOP SWITCH, until engine stops.
Close cooling system manual by-pass valve if opened.
Figure #8
1 - PowerView Gauge
2 - Momentary Display On Switch
3 - Automatic/Manual Mode Selector Switch
4 - ECM Selector Switch
5 - Manual Mode Indicator Warning Light
6 - Alternate ECM Indicator Warning Light
7 - Manual Stop Switch
8 - Manual Crank Switch – Battery #1
9 - Manual Crank Switch – Battery #2
10 – Service Tool Connector
17
2.6.3 Describing Engine Gauge Panel
2.6.3.1 ECM Selector Switch and Primary/Alternate
ECM
Clarke UL/FM Engines come equipped with dual
ECMs and an ECM Selector Switch on engine gauge
panel. (Item #6). Default position of ECM selector
switch is to the Primary ECM. In the event of a
failure of the Primary ECM, where-by the engine shuts
down or will not start, it will become necessary to
manually switch to the Alternate ECM position. When
the ECM Selector Switch is positioned to the Alternate
ECM position a warning light will illuminate at the
engine gauge panel. Also, the main controller will
display a warning light and an audible alarm. The
engine should then be re-started manually. (See
section 2.6.1). Contact a Clarke Authorized Service
Dealer immediately when this situation occurs to
troubleshoot. (See section 7.0).
BASE &
green status
LED
Interior view of engine gauge panel door - BASE
dual ECM auto-switching device and green LED
Figure #9A
Information displayed on the PowerView diagnostic
gauge will come from either the Primary or Alternate
ECM depending upon the position of the ECM
Selector Switch.
If a fault code(s) is displayed and comes from the
Primary ECM, and then the ECM selector switch is
moved to the Alternate ECM position, it may be
necessary to “crank” the engine for the Alternate ECM
to pick-up the same fault code(s).
Interior view of engine gauge panel.
Figure #9B
If the currently selected ECM experiences a failure
detected by the BASE unit, an ECM warning alarm
will be sent to the fire pump controller via interconnect
terminal 303, and will automatically switch to the other
functional ECM. If the automatic switching devices
switches to alternate ECM, a visual indication light
will illuminate on the engine control panel, and an
alternate ECM alarm will be sent to the fire pump
controller via interconnect terminal 301. Upon failure
of the second ECM, the automatic switching device
will alarm an ECM failure alarm to the fire pump
controller via interconnect terminal 304. Additionally,
the BASE status LED will flash at rate of 2 ½ Hz or 25
times in 10 seconds.
2.6.3.2 Dual ECM Automatic Switching
Engine models utilizing dual ECMs are equipped with
a BASE unit (Board for Auto-Switching ECMs) that
can detect failure on either primary or alternate ECM.
The BASE monitors two separate heartbeat signals
from each of the ECMs. If the BASE fails to detect
BOTH of these signals, the BASE will recognize this
as an ECM failure and initiate the automatic ECM
switching process. If the BASE fails to detect only one
of these signals, the automatic ECM switching process
will not initiate however an indication will be made by
a green status LED on the BASE.



Normal Operation: LED Flashes at 1/10 Hz or
1 time in 10 seconds
Primary heartbeat failure only: Led Flashes at
½ Hz or 5 times in 10 seconds.
Secondary heartbeat failure only: LED Flashes
at 1 ½ Hz or 15 times in 10 seconds.
If an ECM failure occurs during engine operation, the
automatic switching device will control engine
shutdown and will prevent starter motor re-engagement
while the engine is shutting down. After the engine
safely comes to a stop the automatic switching device
will switch to the other functional ECM and will then
18
allow starter motor re-engagement control from the fire
pump controller.
The automatic ECM switching process will not initiate
upon failure of any primary, alternate, or non-critical
engine sensors as per UL/FM.
3) This will prevent the BASE from switching to
Alternate ECM during the software re-flashing
process.
4) Complete the programming process as normal.
5) Plug the BASE back in.
After ECM repair, activate the ECM Failure reset
switch to the down position for 3 seconds and release.
This will de-activate the ECM Warning and Failure
alarms to the fire pump controller at interconnect
terminals 303 and 304.
To program the Alternate ECM:
1) Unplug the BASE dual ECM auto-switching
device on the back side of the engine gauge
panel door.
2) Insert the service tool, provided in the engine
gauge panel, into the connector removed from
the BASE. (See Figure #9D)
The hand operated ECM selector switch allows for
manual selection of either primary or alternate ECM.
In the event of failure of the BASE unit while the
ECMs are functional, a Diagnostic Trouble Code of
SPN 2145 FMI 9 will be displayed on the diagnostic
gauge.
2.6.3.3 Programming ECM with Automatic Switching
Device
This procedure will be performed by Clarke Certified
Service Dealer or a Cat Dealer.
In the event of a failed or damaged ECM,
programming will be required on the replacement unit.
The diagnostic tool will be connected to the Service
Tool Connector (#10 in Figure #8). In addition to the
typical programming procedure used on Caterpillar
engines, some extra steps are required.
Figure #9D
3) This will force the panel into Alternate ECM
mode.
4) Complete the programming process as normal.
5) Plug the BASE back in.
To program the Primary ECM:
1) In manual operation mode, select the Primary
ECM with the ECM SELECTOR (#4 on
Figure #8).
2) Unplug the BASE dual ECM auto-switching
device on the back side of the engine gauge
panel door. (See Figure #9C.)
2.6.3.4 Using the PowerView Gauge
The PowerView gauge (reference Figure #9C) allows
the operator to view operating conditions and
diagnostic trouble codes (DTC’s).
Press the menu key (C) to access the various engine
functions in sequence. The displays can be selected as
either customary English or metric units.
The following menu of engine parameters can be
displayed on the power view (refer to Figure #9E).
1.
2.
3.
4.
5.
6.
7.
8.
Figure #9C
19
Engine rpm*
Coolant temperature*
Oil pressure*
Machine hours*
System voltage (battery #1)*
System voltage (battery #2)*
Percent engine load at the current rpm
Oil temperature
9.
10.
11.
12.
13.
14.
Intake manifold temperature
Fuel temperature
Engine torque
Fuel level
Active service (diagnostic) codes
Store service (diagnostic) codes from the
engine
15. Set the units for display
16. View the engine configuration parameters
* These six parameters are fixed for the power-up
display. (See Figure #9F)
The PowerView gauge includes a liquid crystal
display (LCD) screen. The display is programmed
to show six NFPA required engine parameters
simultaneously. The diagnostic gauge uses two
arrow keys (A) and (B) for scrolling through the
engine parameter list and viewing the menu list.
An enter key (E) is used for selecting highlighted
items. The (D) key is an escape option to leave a
menu without making a change. The red (G) and
amber (F) lights are used to signal active trouble
codes received by the diagnostic gauge.
NOTE:


Figure #9F
Main Menu Navigation
NOTE: The display gauge must be powered to
navigate the diagnostic gauge screens. This is
achieved by starting the engine or maintaining upward
pressure on switch #2 from Figure #8. If engine start
up is desired see: Starting the Engine. All the engine
values illustrated in this example, on the diagnostic
gauge, indicate the engine is running.
Red indicator light (G) indicates a serious
condition.
Correct problem before
restarting.
Amber indicator light (F) indicates an
abnormal condition. It is not necessary to
shutdown engine immediately but problem
should be corrected as soon as possible.
1. Starting at the default six-up engine display,
press the “Menu” (C) key.
2. The six items of the “Main Menu” will be
displayed.
Figure #9E
20
3. Pressing the “Arrow” (A&B) keys will scroll
through the menu selections.
3. Each of these parameters can be adjusted by
highlighting the item with use of the “Arrow”
(A&B) keys and then pressing the “Enter” (E)
key to bring up the adjustment screen. See
below for an example of adjusting the
“Brightness”.
User Settings Adjustment
1. From the “Main Menu” screen you can select
“User Settings” by highlighting the text and
pushing the “Enter” (E) key.
2. The following screen will appear. This allows
user adjustment of Brightness, Contrast,
Temperature Units, and Pressure Units.
4. The “Arrow” (A&B) keys become the add and
subtract functions for brightness. Press the
“Enter” (E) key to store the adjustment.
5. Press the “Menu” (C) key to return to the sixup display.
21
User Gauges Adjustment
1. Aside from the six-up default display, there is
an “Auxiliary Parameters” screen that displays
additional engine and system performance
data.
2. Starting at the six-up display, press the “Arrow
Right” (E) key.
1. This screen displays six parameters that are
customizable from a list of 11 user-selectable
parameters. These values are obtained from
the engine ECU via CAN bus protocol. Some
of these parameters may not be able to be
displayed. Compatibility depends on the
specific Clarke engine model you own. To
return to the six-up display from the “Auxiliary
Parameters” screen, press the “Arrow Right”
(E) key once or the “Menu” (C) key twice.
2. To program the parameters displayed on the
“Auxiliary Parameters” screen, start from the
six-up display.
3. The following “Fire Pump Parameters” screen
will appear. This screen will not be populated
with data unless the engine is a Clarke PLD
(Pressure Limiting Driver).
4.
Press the “Arrow Right” (E) key again to
access the “Auxiliary Parameters” screen.
3. Press the “Menu” (C) key to bring up the
following menu.
22
4. The “Main Menu” will be displayed. Press the
“Down Arrow” (B) key to highlight “User
Gauges”. Then press the “Enter” (E) key to
bring up the “User Gauges” screen.
6. Continuing to press the “Arrow Down” (B)
key will bring up another screen with four
more parameters that can be added to the
“Auxiliary Parameters” display.
5. On the “User Gauges” screen, use the “Arrow”
(A&B) keys to highlight the gauge to replace.
Press the “Enter” (E) key and the following
screen will appear.
7. Use the “Arrow” (A&B) keys to highlight the
parameter to add to the “Auxiliary Parameters”
display. Then press the “Enter” (E) key. This
will confirm the selection and recall the “User
Gauges” menu.
23
Engine Settings Data
NOTE: The engine settings data is a read only
function. All engine settings parameters are pre-set by
Clarke. This menu is primarily used for trouble
shooting activities.
1. Starting at the six-up display, press the
“Menu” (C) key.
8. In this example, the “CAC TEMP” parameter
has been switched to the “COOLANT
LEVEL” parameter. Pressing the “Menu” (C)
key from this screen will return the display to
the default six-up display.
9. The following screen is a key depicting the
locations of Gauge 1 - Gauge 6 on the
“Auxiliary Parameters” display.
2. The main menu will be displayed. Use the
“Arrow” (A&B) keys to scroll through the
menu until “Engine Settings” is highlighted.
10. To return to the six-up display from the
“Auxiliary Parameters” screen, press the
“Arrow Right” (E) key once or the “Menu” (C)
key twice.
3. Once “Engine Settings” menu item has been
highlighted, press the “Enter” (E) key to view
the following screen.
24
4. Pressing the “Enter” key will access the
following screen. It displays two numbers.
The upper number is the engine speed (RPM)
required to trip the overspeed alarm during a
verification of that alarm circuit. The lower
number is the engine speed (RPM) required to
activate the overspeed alarm during normal
operation.
6. Press the “Menu” (C) key to return to the main
menu.
Accessing Stored Trouble Codes
1. Starting at the six-up display, press the
“Menu” key.
5. Pressing the “Escape” (D) key will return you
to the “Engine Settings” menu. Press the
“Arrow” (B) key to highlight “Software
Revision”. Then press the” Enter” (E) key.
The following screen will appear.
This
information may be requested during an
attempt to troubleshoot an issue.
2. The main menu will be displayed. Use the
“Arrow” (A&B) keys to scroll through the
menu until “Faults” is highlighted.
25
5. The top line of the “Stored Faults” screen
informs the user of the number of stored fault
codes. If there are two stored faults, beside the
text “Diagnostic Message”, the text will read 1
of 2. SPN and FMI make up the code for the
fault. See the Troubleshooting section of this
manual for description of common codes. OC
is the number of occurrences for the code
displayed.
6. See below for an example of a “Stored Faults”
screen when there are stored faults. Press the
“Arrow” (A&B) keys to scroll through all of
the stored fault codes. Press the “Menu” (C)
key once to return to the “Main Menu”. Press
again to return to the six-up display.
3. Press the “Enter” (E) key once “Faults” is
highlighted and the “Faults” menu will appear.
4. Press the “Arrow” (A&B) keys to highlight
“Stored Faults” and press the “Enter” (E) key.
The following screen will appear.
26
Accessing Active Trouble Codes
3. If the arrows appear above keys A&B, there
are more trouble codes that can be viewed by
using the arrow keys to scroll to the next
trouble code. It will also indicate multiple
“Diagnostic Messages” at the top of the screen.
Ex. (1 of 2 instead of 1 of 1.)
For description of trouble codes, see chart in
Troubleshooting Section.
1. During normal operation, the default six-up
display will be visible.
4. To acknowledge and hide the code and return
to the six-up display, press the “Enter” Key.
2. When the diagnostic gauge receives a trouble
code from an engine control module, the sixup display will be replaced with the “Warning”
message. The SPN and FMI number will be
displayed along with a description of the
problem. The yellow LED on the left will be
illuminated as well.
IMPORTANT: Ignoring active trouble codes can
result in severe engine damage.
5. The screen will return to the six-up display, but
the display will contain the warning icon. The
yellow LED will also remain illuminated. The
warning icon and yellow LED will remain in
place until the fault condition is corrected.
6. To view the active code(s) again, press the
“Menu” (C) key to display the “Main Menu”.
27
2. When the diagnostic gauge receives a severe
trouble code from an ECM, the six-up display
will be replaced with the “Shutdown” message,
The SPN and FMI number will be displayed
along with a description of the problem.
7. Press the “Down Arrow” (B) key two times to
highlight the “Faults” option. Then press the
“Enter” (E) key to access the “Faults Menu”.
8. With “Active Faults” highlighted, press the
“Enter” (E) key. The first “Active Fault”
screen will appear.
3. To acknowledge and hide the trouble code and
return to the six-up display, press the “Enter”
key.
Engine Shutdown Codes
Note: For Clarke Engine models, the only shutdown
will be due to an overspeed condition.
1. During normal operation, the six-up display
will be viewed.
28
2014, reprint provided below, for guidance to the
minimum requirements for fuel maintenance for all
Clarke fire pump engine installations.
The following is reprinted from the “NFPA 25 2014
Standard for the Inspection, Testing, and maintenance
of Water-Based Fire Protection Systems,” Copyright ©
2013 National Fire Protection Association®. All
Rights Reserved.
8.3.4 Diesel Fuel Testing and Maintenance
8.3.4.1 Diesel fuel shall be tested for
degradation no less than annually.
8.3.4.1.1* Fuel degradation testing shall
comply with ASTM D975-11b Standard
Specification for Diesel Fuel Oils, or ASTM
D6751 -11b Standard Specification for
Biodiesel Fuel Blend Stock (B100) for Middle
Distillate Fuels as approved by the engine
manufacturer, using ASTM D 7462 -11
Standard Test Method for Oxidation Stability
of Biodiesel (B100) and Blends of Biodiesel
with Middle Distillate Petroleum Fuel
(Accelerated Method).
8.3.4.2* If diesel fuel is found to be deficient in
the testing required in 8.3.4.1.1, the fuel shall
be reconditioned or replaced, the supply tank
shall be cleaned internally, and the engine fuel
filter(s) shall be changed.
8.3.4.2.1 After the restoration of the fuel and
tank in 8.3.4.2, the fuel shall be retested each 6
months until experience indicates the fuel can
be stored for a minimum of one year without
degradation beyond that allowed in 8.3.4.1.1
4. The gauge will return to six-up display, but the
display will contain the “Shutdown” icon. See
the process for accessing “Active Faults” to
display the shutdown code again.
5. The six-up display screen will contain the
shutdown icon until the trouble code condition
is corrected. For Clarke engines, the only
shutdown condition is engine overspeed. See
Section 3.5.3 for overspeed reset.
6. The engine will not restart and run until the
overspeed reset procedure is performed.
3.0 ENGINE SYSTEMS
3.1 FUEL SYSTEM
3.1.1
Diesel Fuel Specification
All diesel fire pump drivers manufactured by Clarke
are designed, tested and warranted for use only with
No. 2-D Diesel Fuel conforming to ASTM
International D-975-11b or British Standard
BS2869:2010+A1:2011 Fuels oils for agricultural,
domestic and industrial engines and boilers Specification.
8.3.4.3
When
provided,
active
fuel
maintenance systems shall be listed for fire
pump service.
8.3.4.3.1 Maintenance of active fuel
maintenance systems shall be in accordance
with the manufacturer’s recommendations.
Although the above referenced fuel specifications
allow limited amounts of Biodiesel, 100% petroleum
fuel is preferred and should be used whenever possible.
Biodiesel in any amount greater than that allowed by
the above referenced specifications should not be used.
The use of fuels not referenced above, or Biodiesel in
amounts greater than allowed in the above referenced
specifications, may affect performance and reliability,
and may result in a non-warrantable engine condition.
8.3.4.3.2 Maintenance of active fuel
maintenance systems shall be performed at a
minimum annual frequency for any portion of
the system that the manufacturer does not
provide
a
recommended
maintenance
frequency.
To insure engine reliability and performance, the fuel
provided for Clarke fire pump drivers must be
maintained in a quality condition. Refer to NFPA 25
8.3.4.3.3 Fuel additives shall be used and
maintained in accordance with the active fuel
29
maintenance
system
recommendations.
manufacturer’s
3.1.2
Bleeding the Fuel System
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury. Relieve
pressure before disconnecting fuel or other lines.
Tighten all connections before applying pressure.
Keep hands and body away from pinholes and
nozzles, which eject fluids under high pressure. Use
a piece of cardboard or paper to search for leaks.
Do not use your hand.
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a doctor
familiar with this type injury or gangrene may
result. Ref figure #10
A.8.3.4.1.1 Commercial distillate fuel oils used
in modern diesel engines are subject to various
detrimental effects from storage. The origin of
the crude oil, refinement processing
techniques, time of year, and geographical
consumption location all influence the
determination of fuel blend formulas.
Naturally occurring gums, waxes, soluble
metallic soaps, water, dirt, blends and
temperature all contribute to the degradation
of the fuel as it is handled and stored. These
effects begin at the time of fuel refinement and
continue
until
consumption.
Proper
maintenance of stored distillate fuel is critical
for engine operation, efficiency, and longevity.
Storage tanks should be kept water-free. Water
contributes to steel tank corrosion and the
development of microbiological growth where
fuel and water interface. This and the metals of
the system provide elements that react with
fuel to form certain gels or organic acids,
resulting in clogging of filters and system
corrosion. Scheduled fuel maintenance helps
to reduce fuel degradation. Fuel maintenance
filtration can remove contaminants and water
and maintain fuel conditions to provide
reliability and efficiency for standby fire pump
engines. Fuel maintenance and testing should
begin the day of installation and first fill.
Figure #10
IMPORTANT: Fuel filter must be replaced according
to maintenance schedule (See Section 4.0) or when
trouble code indicates plugged filter (fuel supply
pressure moderately/extremely low).
3.1.2.1 Priming C18 Engine Series when secondary
filter has been changed:
1) Open the air purge screw (2) three full turns.
Do not remove screw. The air purge screw is
located on the secondary filter base. See
Figure #12.
2) Start the engine. The engine should start and
run smoothly. Never crank the engine for
more than 30 seconds continuously. Allow the
starter motor to rest for 2 minutes after 30
seconds of cranking. You may use the hand
priming pump (1), in lieu of starting the
engine. The priming pump is located on the
primary filter base on your Clarke C18 engine.
See Figure #11.
3) While the engine is running, monitor the air
purge screw (2). When a small drop of fuel
appears at the threads, turn and tighten air
purge screw. The tone of the engine may
change as the screw is tightened, this is
normal.
4) Clean residual fuel from all engine
components.
A.8.3.4.2 Where environmental or fuel quality
conditions result in degradation of the fuel
while stored in the supply tank, from items
such as water, micro-organisms and
particulates, or destabilization, active fuel
maintenance systems permanently installed on
the fuel storage tanks have proven to be
successful at maintaining fuel quality. An
active fuel maintenance system will maintain
the fuel quality in the tank, therefore
preventing the fuel from going through
possible cycles of degradation, risking engine
reliability, and then requiring reconditioning.
30
3.1.3
Changing the Fuel Filters
3.1.3.1 C18 Engine Series
Each engine has two fuel filters. For identity, the
primary filter incorporates the transparent water
separator. Both primary and secondary filters must be
replaced at the same time.
Replacing Primary Fuel Filter/Water Separator
1) Close fuel shut-off valve at bottom of fuel
tank, if equipped.
2) Thoroughly clean filter base (4) and
surrounding area to keep from getting dirt and
debris into fuel system. See Figure#13.
3) Remove element (1) from the mounting base
while bowl (2) is still attached.
4) Dispose of the filter contents appropriately.
Remove bowl (2) from element (1). The bowl
is reusable, do not discard. Dispose of the
used element.
5) Remove the o-ring from the gland of the bowl.
Clean the bowl and the o-ring. Inspect the oring for damage or deterioration. Replace if
necessary.
6) Lubricate the o-ring with clean diesel fuel.
7) Install bowl (2) on a new element. Tighten the
bowl by hand. Do not use tools to tighten the
bowl.
8) Lubricate the top seal of the element (1) with
clean diesel fuel. Install the new element on
the filter base. Tighten the element by hand.
9) Ensure the drain (3) is in the closed position.
10) Open the fuel shut-off valve at the bottom of
the fuel tank, if equipped.
11) Start the engine and check for leaks. Run the
engine for 1 minute. Stop the engine and
check for leaks again.
12) The primary filter/water separator is under
suction. A leak will allow air to enter the fuel.
Aerated fuel can cause loss of power.
Figure #11
Figure # 12
3.1.2.2 Priming C18 Engine Series when the engine
has been run out of fuel:
Note: Additional steps must be taken to prime the
engine when the engine has ceased to run due to an
exhausted fuel supply.
1) Fill the fuel tank with clean diesel fuel of the
appropriate grade.
2) Open the air purge screw (2) three full turns.
Do not remove screw.
3) Crank the engine for 30 seconds. Then allow
the starter to rest for 2 minutes. Use a suitable
container to catch fuel flow from the air purge
screw bore. You may use the hand priming
pump (1), in lieu of starting the engine. See
Figure #11.
4) Crank the engine for 30 seconds. Allow the
starter to cool for 2 minutes.
5) Repeat step 4 until the engine starts and runs.
6) Clean any residual fuel from all engine
components.
Replacing Secondary Fuel Filter Element
1) Stop the engine. Close fuel shut-off valve at
bottom of fuel tank, if equipped. Disconnect
battery power.
2) It may be necessary to relieve residual fuel
pressure from the fuel system before the fuel
filter is removed. Wait 1 to 5 minutes until the
fuel pressure is lowered. Use a suitable
container to catch any fuel that may spill.
3) Remove and discard the used filter.
31
4) Apply clean diesel fuel to the new filter orings.
5) Install the new fuel filters. Spin the fuel filter
onto the filter base until the o-ring makes
contact. Use the rotation index marks on the
filters as a guide for proper tightening.
Tighten filters according to the instructions
that are on the fuel filters. Do not overtighten
the filters.
6) Open the fuel supply valve. The engine will
need to be purged of air. Refer to Section
3.1.2.1 for fuel system priming instructions.
3.2 AIR/EXHAUST SYSTEM
3.2.1 Ambient Conditions
Clarke engines are tested in accordance with SAE
J1349 (Clarke USA) or ISO 3046 (Clarke UK). In this
capacity, they may be de-rated to meet certain site
conditions, failure to do so can seriously impede the
performance of the engine and could lead to premature
failure.
3.2.2 Ventilation
The engine must be provided with adequate ventilation
to satisfy the requirements of the combustion system,
radiator cooling systems where fitted, and allow
adequate dissipation of radiated heat and crankcase
emissions. For all this data refer to Installation &
Operation Data (see Page 5). This data can be used for
proper sizing of inlet and outlet louvers.
3.2.3 Standard Air Filter
The standard air filter is a reusable type. Should a
situation occur where the air filter becomes plugged
with dirt (starving the engine of air), loss of power and
heavy black smoke will result; the air filter should be
serviced immediately. See Appendix A for air filter part
numbers by Clarke Engine Model. The maximum
intake air restriction allowed, per engine model, can be
seen in the following table.
CAUTION: Do not attempt to remove the air filter
while an engine is running nor run the engine while the
air filter is off. Exposed components could cause
severe injury to personnel and major internal engine
damage could occur should any foreign matter be
drawn into the engine.
Figure #13 – Primary Filter Assembly
3.1.4 Fuel Tanks
Keep the fuel tank filled to reduce condensation to a
minimum. Open drain at the bottom of the fuel tank
once a week to drain off any possible water and/or
sediment. Fill tank after each test run.
The air filter manufacturer recommends the following:
1) The pre-oiled reusable elements are serviced
with a special oil. The elements can be
serviced or replaced.
2) Figure #14 shows the air filter service
instructions.
3) When servicing the element is not practical,
you can improve filter efficiency by respraying with oil.
Note: Per NFPA 25 standards, the fuel tank level must
never be less than 67% of its capacity.
Maximum Allowable Fuel Head above Fuel lift pump,
Supply or Return.
Engine model
C18
feet
15.0
NOTE: Do not attempt this while engine is running.
NOTE: Do not over oil the reusable element
meters
4.57
32
Engine model
Air filter
restriction limit
(inches of water)
C18H0-UFAD50
C18H0-UFAD58
C18H0-UFAD68
25
C18H0-UFAD70
C18H0-UFAD78
C18H0-UFAD10
C18H0-UFAD18
C18H0-UFAD20
C18H0-UFAD28
C18H0-UFAD30
C18H0-UFAD38
C18H0-UFAD40
30
C18H0-UFAD48
C18H0-UFAA78
C18H0-UFAC10
C18H0-UFAC18
C18H0-UFAC20
C18H0-UFAC28
Figure #14
Note: Intake Air Shutoff Valve - Engine may
include an intake air shutoff valve as an optional
feature that is activated by an overspeed event and
provides a positive shutoff of combustion air to the
engine. The optional air intake shutoff valve has
not been evaluated by UL as part of a UL Listed
fire pump driver.
3.2.4 Crankcase Ventilation
Vapors that form within the engine are removed from
the crankcase and gear train compartment by a
continuous, pressurized ventilation system. A slight
pressure is maintained within the engine crankcase
compartment. Vapors are expelled through a vent pipe
attached to the rocker cover. Ref. Figure #15. Contact
Clarke for an optional breather kit if vapors accumulate
in your pump room.
33
The installation of the exhaust system should consist of
the following:
 Personnel protection from hot surfaces.
 Adequate supports to prevent strain on the
engine exhaust outlet and minimize vibration.
 Protection against entry of water and other
foreign matter.
While the engine is running inspect exhaust pipe outlet
outside of the pump room itself for environmental
hazards such as excessive smoke conditions. The
following could be used as a guide for general engine
operating conditions.
1) Blue Smoke – Possible engine oil
consumption.
2) White Smoke – Possibility of water in
cylinders, water in fuel or internal engine
problem.
Figure #15
3.2.5 Exhaust System
Excessive back pressures to the engine exhaust can
considerably reduce both engine performance and life.
It is important that exhaust systems are the proper
diameter, as short as possible, and with a minimum of
bends. Refer to Installation & Operating Data (See
www.clarkefire.com) for exhaust data. Also refer to
the table below for maximum exhaust restrictions.
Engine model
3.3 LUBRICATION SYSTEM
3.3.1 Checking Sump Oil
Check the sump oil level using the dipstick on the
engine as shown in Figure #16.
Exhaust
backpressure limit
(inches of water)
C18H0-UFAC10
C18H0-UFAC18
C18H0-UFAC20
C18H0-UFAC28
C18H0-UFAD10
C18H0-UFAD18
C18H0-UFAD20
C18H0-UFAD28
C18H0-UFAD30
C18H0-UFAD38
40
Figure #16
C18H0-UFAD40
C18H0-UFAD48
This level must always be between the dipstick marks
Min. and Max. with the engine not running. See
Figure #17.
C18H0-UFAD50
C18H0-UFAD58
C18H0-UFAD68
C18H0-UFAD70
C18H0-UFAA78
C18H0-UFAD78
34
3.3.4 Oil Specification
Diesel Engine Oil
This engine is filled at Clarke with SAE 15W-40 oil
meeting CAT ECF-3 specification.
Important: Do not add makeup oil until the oil
level is BELOW the add mark on dipstick. Add Cat
DEO 15W-40 or equivalent when makeup oil is
required.
3.3.5 Oil Capacities (Including Filters)
ENGINE
MODEL
C18 – All Models
Figure #17
3.3.2 Changing Engine Oil
1) Operate the engine until it is warm.
2) Stop the engine. Remove the sump drain plug
and drain the lubricating oil from the sump.
Fit the drain plug and tighten the plug to 34
Nm (25lb-ft) (3.5 kgf-m).
3) Fill the sump to the ‘FULL” mark on the
dipstick with new and clean lubricating oil of
an approved grade.
4) Dispose used oil properly.
OIL CAPACITY
QUARTS (LITERS)
48.0 (45.4)
3.4 COOLING SYSTEM
3.4.1 Intended Engine Operating Temperature
The C18 engines are provided with either a heat
exchanger or radiator to maintain the engine coolant
temperature within recommended operating guidelines.
The C18 models have an intended engine operating
temperature of 190º F (88ºC) to 205º F (96º C). A high
coolant temperature sensor monitors coolant
temperature and will set an alarm at 217º F (103º C).
3.3.3 Changing Oil Filter Cartridge
1) Put a tray under the filter to retain spilt
lubricating oil.
2) Remove the filter with a strap wrench or
similar tool.
Then dispose of the filter
properly.
3) Clean the filter head.
4) Add clean engine lubricating oil to the new
filter. Allow the oil enough time to pass
through the filter element.
5) Lubricate the top of the filter seal with clean
engine lubricating oil.
6) Fit the new filter and tighten it by hand only.
Do not use a strap wrench.
7) Ensure that there is lubricating oil in the sump.
On turbocharged engines, ensure that the
engine will not start and operate the starter
motor until oil pressure is obtained.
8) Operate the engine and check for leakage from
the filter. When the engine has cooled, check
the oil level on the dipstick and put more oil
into the sump, if necessary.
9) Return the unit back into service by returning
the main pump controller selector to
“automatic” position and the manual operating
lever to AUTO-OFF position.
3.4.2 Engine Coolant
The following information is provided as a guide for
Caterpillar Engine users in the selection of a suitable
coolant.
The water/ethylene glycol/inhibitor coolant mixture
used in Caterpillar engines must meet the following
basic requirements:
 Provide for adequate heat transfer.
 Provide protection from cavitation damage.
 Provide
a
corrosion/erosion-resistant
environment within the cooling system.
 Prevent formation of scale or sludge deposits
in the cooling system.
 Be compatible with engine hose and seal
materials.
 Provide adequate freeze and boil over
protection.
WARNING
A water and anti-freeze solution is required for
pump installations. Premixing this solution prior to
installing is required. This prevents possible pure
35
anti-freeze chemical reactions to block heater
elements which can burnout the element. Please see
the I&O section (see Page 5) for proper cooling
system capacities of each model.
A 50% coolant water solution is recommended. A
concentration over 70% is not recommended because
of poor heat transfer capability, adverse freeze
protection and possible silicate dropout.
Concentrations below 30% offer little freeze, boil over
or corrosion protection.
3.4.3 Water
Water can produce a corrosive environment in the
cooling system, and the mineral content may permit
scale deposits to form on internal cooling surfaces.
Therefore, inhibitors must be added to control
corrosion, cavitation, and scale deposits.
IMPORTANT
Never use automotive-type coolants (such as those
meeting only ASTM D3306 or ASTM D4656).
These coolants do not contain the correct additives
to protect heavy-duty diesel engines. They often
contain a high concentration of silicates and may
damage the engine or cooling system.
Chlorides, sulfates, magnesium and calcium are among
the materials which make up dissolved solids that may
cause scale deposits, sludge deposits, corrosion or a
combination of these. Chlorides and/or sulfates tend to
accelerate corrosion, while hardness (percentage of
magnesium and calcium salts broadly classified as
carbonates) causes deposits of scale. Water within the
limits specified in figure #17 is satisfactory as an
engine coolant when properly inhibited. Use of
distilled water is preferred.
Materials
Chloride (Max.)
Sulfates (Max.)
Total Dissolves Solids
(Max.)
Total Hardness (Max.)
Milligram
per Liter
40
100
Grains
per
Gallon
2.4
5.9
340
20
170
10
ENGINE
MODEL
C18-All Models
COOLANT
CAPACITY
QUARTS (LITERS)
40 (37.9)
3.4.5 Coolant Inhibitors
The importance of a properly inhibited coolant cannot
be over-emphasized. A coolant which has insufficient
or no inhibitors at all, invites the formation of rust,
scale, sludge and mineral deposits. These deposits can
greatly reduce the cooling systems efficiency and
protection capabilities.
Recommended supplemental coolant inhibitors are a
combination of chemical compounds which provide
corrosion protection, cavitation suppression, pH
controls and prevents scale. These inhibitors are
available in various forms, such as liquid packages or
integral parts of an extended life coolant.
3.4.4 Coolant Capacities
It is imperative that inhibitors are used in all Caterpillar
engine cooling systems. A pre-charge dosage must be
used at the initial fill with a conventional coolant, that
is not fully formulated, and the maintenance dosage
must be added at each service interval. Conventional
coolants must meet ASTM D4985 or ASTM D6210 to
be used in Cat engines. Conventional coolants rely on
inorganic inhibitors and are (re)charged with a
Supplemental Coolant Additive (SCA)
Ethylene Glycol or Propylene Glycol are acceptable:
IMPORTANT:
Do not use cooling system sealing additives or
antifreeze that contains sealing additives.
Do not mix ethylene glycol and propylene glycol base
coolants.
An extended life coolant that meets ASTM D4985 or
ASTM D6210 and contains less than 125 ppm of
silicon (present as silicate) can be used in Cat engines
to the recommended maximum service life. Extended
life coolants rely on organic inhibitors and are
recharged with an Extender. Extenders are typically
added at one half the service life of the coolant.
Use an ethylene glycol coolant (low silicate
formulation) that meets the standard of ASTM E1177
or propylene glycol that meets ASTM D6210
requirements. Use of propylene glycol requires
addition of CAT SCA (Supplemental Coolant
Additive) to prevent liner cavitation.
36
Inhibitors become depleted through normal
operation; additional inhibitors must be added to
the coolant as required to maintain original
strength levels.
To properly check inhibitor concentration, it may be
necessary to contact your local Service/Dealer for
assistance. Refer to Parts Information Section to
obtain the part number for the factory Coolant Analysis
Kit. This kit can be purchased for a nominal fee for
analyzing the conditions of the engine’s coolant.
3.4.6 Procedure for Filling Engine
During filling of the cooling system, air pockets may
form. The system must be purged of air prior to being
put in service. This is best accomplished by filling
with a pre-mix solution. Refer to Figure #18 for proper
fill level.
Figure #18
3.4.7 Providing Adequate Raw Water Supply to the
Engine Heat Exchanger
Caution: Do not overfill cooling system. A
pressurized system needs space for heat
expansion without overflowing.
3.4.7.1 Raw Water Supply
Most Clarke diesel engine fire pump drivers are heat
exchanger cooled and some engines also have a charge
air cooler (CAC) that uses raw water to cool the air
before entering the intake manifold. If you have a
radiator cooled Clarke engine, you can disregard this
section. Heat exchanger cooled diesel engine drivers
require a clean source of pressurized water from the
discharge side of the fire pump. To prevent
overheating, the loop must provide a specified
minimum amount of raw water flow.
Install the pressure cap, start and run engine for
approximately 5 minutes to purge the air from the
engine cavities.
When verifying that the coolant is at a safe operating
level, it is best to wait until the engine temperature
drops to approximately 120ºF (49ºC), or lower, before
removing the pressure cap.
Remove the pressure cap and refill to the proper fill
level. To continue the de-aeration process, start and
run engine until the temperature stabilizes at
approximately 160°-200° (71°-93° C) or run engine for
25 minutes, whichever is longer. During this warming
process, you may see coolant coming from the
overflow tube attached at the pressure cap location.
Allow engine to cool, then remove the pressure cap
and refill to the proper fill level.
3.4.7.2 Cooling Loop
Note: Engine may include a cooling loop as an
optional feature and has not been evaluated by UL
as part of a UL Listed fire pump driver.
Clarke cooling loops are FM Approved to meet
standard sizing conditions of 50% blocked wye
strainers, 100degF (38degC) raw water inlet
temperature, 80 psi inlet pressure, and 10 psi
available at the engine outlet.
Caution: Do not remove pressure cap while coolant is
at normal operating temperatures. Possible personal
injury could result from the expulsion of hot coolant.
Figure #19 shows the standard NFPA 20 cooling loop
piping arrangement. The cooling loop consists of an
Automatic flow line with a 12v or 24v solenoid valve
(HSC and ES pump applications only) that is energized
to open anytime the engine is called upon to run from
either the fire pump controller or from the engine
gauge panel.
37
NOTE: VT type pump applications do not require a
solenoid valve in the Automatic flow line.
In each flow line, there is also a pressure regulator.
Each pressure regulator protects the downstream
piping from over-pressurization which includes the
tube side of the engine shell & tube heat exchanger
(and/or CAC) and to control raw water flow rate. The
pressure regulators are set to limit downstream
pressure to 60 psi (4 bar). There is a 0-60 psi (0-4 bar)
pressure gauge installed at the cooling loop outlet, and
prior to the engine heat exchanger (or CAC).
The second flow line is called the Manual by-pass line
and it can be opened at any time if for any reason the
engine shows signs of overheating. Each line has two
(quarter turn) shutoff values installed and the normal
position of the shutoff valve is to remain open in the
Automatic flow line and remain closed in the Manual
by-pass flow line.
Wye strainers are used to remove debris from the raw
water supply. One strainer is in the Automatic flow
line and the other is in the Manual by-pass flow line.
Note: See section 3.4.7.5 regarding strainer
maintenance.
NOTE: Opening both lines to flow is never a problem
should there be some concern of engine overheat,
especially if there is an emergency situation. The
Manual by-pass line can only be opened by an
operator in the pump room.
The shutoff valves are all identified to show which are
Normally Open (Automatic flow line) and which are
Normally Closed (Manual by-pass flow line). The
shutoff valves are also used to isolate water pressure in
the event of maintenance to pressure regulators,
strainers and solenoid valve. Shut off valves in the
Automatic flow line are provided with lockable
handles for cooling loops that have been tested to FM
requirements.
Figure #19
38
3.4.7.3 Setting Raw Water Flow Rate
3.4.7.4 Raw Water Outlet
The proper amount of raw water flow thru the
engine is of the utmost importance, and the
pressure gauge value does little to indicate if there
is sufficient flow. When the engine is exercised
weekly, the amount of raw water flow exiting the
engine should always be checked to verify it does
not appear to have diminished.
NOTE: NFPA 20 does allow for the heat exchanger
outlet flow to be returned to a suction reservoir. This
makes it very difficult to measure the flowrate.
When discharging to a suction reservoir, NFPA
provides additional requirements:
1) A visual flow indicator and temperature
indicator are installed in the discharge (waste
outlet) piping.
2) When waste outlet piping is longer than 15ft
(4.6m) and / or the outlet discharges are more
than 4ft (1.2M) higher than the heat
exchanger, the pipe size increased by at least
one size.
3) Verify that when the correct flow rate is
achieved that the inlet pressure to the heat
exchanger (or CAC) does not exceed 60psi
(4bar)
During initial commissioning of the engine, it is
important to correctly set the raw flow rate going thru
the cooling loop. Each Clarke engine model has an
Installation and Operation (I&O) Datasheet that
provides basic operating conditions of the engine and
most values are given based upon engine speed. You
will find this datasheet in the documentation bag that
is shipped with the engine for your specific Clarke
model. This datasheet must be available during
commissioning to set the proper minimum raw water
flow. With the fire pump flowing 150% of rated
flow, and the Automatic flow line open; verify
sufficient raw water flow rate is achieved and that the
reading of the cooling loop pressure gauge does not
exceed 60 psi (4 bar). You will need to capture the
If you have such an installation, it is recommended
that you run the engine for a period of time at fire
pump 150% flow and confirm the visual flow
indicator is showing water flow, the temperature rise
is not excessive (usually no more than 60°F (27°C)
over ambient raw water temperature), and the engine
is showing no signs of overheating.
flow for a specific amount of time coming out of the
heat exchanger and going to a floor drain to establish
a reasonably accurate flow rate value. Using a
container or bucket of known volume, record the time
required to fill the container and compare to the gpm
or L/min value provided on the I&O datasheet. THIS
IS CRITICAL FOR PROPER ENGINE COOLING
AT MAXIMUM PUMP LOAD!!
If proper cooling water flow rate is established then
no fire pump controller alarm will be triggered to
indicate clogged raw water strainer (low raw water
flow).
After verifying raw water flow rate in the Automatic
flowline, open the Manual by-pass line shut-off
valves, and then close the Automatic flowline shutoff valves and repeat the above process to verify the
flowrate going thru the Manual by-pass line. Note,
with Automatic flowline closed the controller low
raw water flow alarm may be present, this is normal.
Once this is completed; close the Manual by-pass
shut-off valves and open the Automatic flowline
shut-off valves to restore conditions back to normal.
3.4.7.5 Raw Water Quality Strainers and
Deterioration of Heat Exchanger (or CAC)
Over time, as the heat exchanger (or CAC) begins to
plug and foul, this pressure will rise and the flow will
diminish which could mean that the heat exchanger
(or CAC) may have to be replaced.
It can be not stressed enough how important it is to
keep the wye strainers within the cooling loop clean:
Most engine failures occur due to plugged cooling
loop strainers! If the raw water supply has debris in
it (leaves, stones, etc.) as the strainer accumulates
more debris (that will not pass thru it), the flowrate
will continue to diminish which will eventually starve
the engine of adequate cooling water flow which will
lead to engine overheat and catastrophic engine
failure. When this occurs, you have no fire
protection! Clarke recommends that after the initial
engine commissioning and prior to each weekly
exercise of the engine / fire pump set, both strainers
be removed and cleaned and then re-installed before
starting the engine.
39
Clarke engines are equipped with an alarm that is
meant to signal diminished raw water flow rate
(terminal 311), possibly due to clogged raw water
strainers in the cooling loop. Refer to Figure #20 for
location of sensors. A circuit board located near the
front of the cooling loop monitors differential
pressure between the two sensors and will send an
alarm to the controller if a low water flow condition
exists.
3.4.7.7 Raw Water Outlet Temperature
Certain local codes may not allow you to discharge
the waste water outlet from the engine heat
exchanger either due to its temperature or it now
being considered hazardous waste. It is
recommended you always check local codes
regarding waste water discharge.
3.4.8 Flow Paths of Engine Cooling System
Additionally, a raw water temperature switch will
send an alarm (terminal 310) when temperature of the
water exceeds 105°F (41° C). Refer to Figure #20
for location of switch. If either of these alarms are
active, it indicates that the cooling system’s
capability may be compromised.
The engine coolant flows through the shell side of the
heat exchanger (or radiator), engine coolant pump, oil
cooler, turbo chargers, engine block and cylinder
head, jacket water heater, thermostat, expansion tank,
and coolant recovery tank (if equipped).
On heat exchanger equipped engines raw cooling
water flows through the tube side of the charge air
cooler, if equipped, and the tube side of the heat
exchanger.
Refer to Figures #21A for heat exchanger cooled
engines and #21B for radiator cooled engines for
cooling system flow path diagram.
Figure #20A
3.4.7.6 Backflow Preventers
NFPA 20 allows for the use of backflow preventers
in the Automatic and Manual flow line of the cooling
loop as required by local code. For specific
application information contact factory.
40
Figure 21A – Heat Exchanger cooled engines
Figure 21B- radiator cooled engines
41
3.4.9 IMPORTANT SERVICE NOTICE
3.5.2 Checking Drive Belt Tension and Adjustment
Any time an engine experiences a high coolant
temperature alarm condition the primary cause of the
overheat must be determined and the cause corrected
to prevent a recurring overheat event. Additionally,
if an event of a restricted flow, collapsed hose,
insufficient coolant level or failed pressure cap is
experienced, further investigation of the cooling
system is required.
All drive belts must be adequately tightened to ensure
that the battery charging alternator is operating
efficiently. Refer to Figure #22.
A
1) The coolant shoud be drained (after deenergizing the coolant heater
2) Replace the engine thermostat(s)
3) Remove the engine water pump
and inspect the impeller and seal for damage, replace
as necessary. Reassemble and refill coolant
according to the Installation and Operations
Instruction Manual.
4) Run the engine to verify normal operating
temperature.
Figure #22
3.4.9.1 Water Pump Cavitation
To adjust Belt Tension:
Cavitation is a condition that occurs when bubbles
form in the coolant flow in the low pressure areas of
the cooling system and implode as they pass to the
higher pressure areas of the system. This can result in
damage to cooling system components, particularly
the water pump impeller and cylinder liners.
Cavitation in an engine can be caused by:
Check belt tension:
- Give at arrow C must be approx. 0.5” (12.7mm).
To increase tension of the alternator driving belt:
- Loosen nut at D.
- Loosen nut B on adjustment rod.
- Tighten nut A to push the alternator to the right to
tighten the belt. Do NOT overtighten the belt.
- Tighten mounting nut B to lock adjustment
in place.






3.5
Improper coolant
Restricted coolant flow caused by collapsed
hose or plugged system
Coolant fill cap is loose or unable to retain
the required pressure
Insufficient fluid level
Failure to de-aerate
Overheat
3.5.3 Engine Overspeed
In the event of an engine overspeed, the ECM signals
the main pump controller and also affects an engine
shutdown. Should an overspeed condition occur,
investigate the cause and make necessary corrections
before placing engine back in service. The overspeed
reset switch must be manually lifted for 30 seconds to
reset. After reset, the Powerview Gauge will display
“no data” for engine parameters. Cycle the ECM
selector switch to Alternate ECM and back to
Primary ECM before attempting to restart the engine.
ELECTRICAL SYSTEM
3.5.1
Wiring Diagrams (Only with Engine Gauge
Panel)
Drawing No.
C072753
C072736
C072753
Drawing No.
C07651
Description
(DC Voltage)
Instrument Panel
ECM Harness
C18-all models
Engine Harness
Description
(AC Voltage)
Jacket Water Heater
OVERSPEED VERIFICATION
Reference
Document
Hold the OVERSPEED VERIFICATION switch in
the “up” position. This will provide the main pump
controller with an overspeed signal and engine
shutdown at 30 RPM’s below the rated RPM.
Reference
Document
Start the engine via the main pump controller; the
speed switch will generate an overspeed signal and
shutdown protecting both the engine and pump.
42
EXAMPLE
Rated Speed: 1760 RPM
Overspeed Shutdown: 2112 RPM (120% of
1760 RPM)
Verification Shutdown: 1730
engine to prevent it from starting. Shutting
off the fuel supply will cause an air lock
condition in the fuel system and possibly
cause fuel system component damage.
CAUTION: After verification of overspeed, lift the
OVERSPEED RESET switch and reset the main
pump controller to re-instate normal operation of the
engine and speed switch. Cycle the ECM selector
from the ECM in use to the other ECM and back
again after lifting the OVERSPEED RESET.

Alarm 5: Low Engine Coolant Temperature:
With engine at rest, lift low coolant
temperature switch for 25 seconds.

Alarm 6: ECM Warning: Lift the
OVERSPEED RESET SWITCH for 2
minutes with engine not running to verify
ECM Warning Alarm; note engine will
automatically switch to alternate ECM.

Alarm 7: ECM Failure: After ECM Warning
Alarm has been tested, continue lifting
OVERSPEED RESET SWITCH for
additional 2 minutes with engine not running
to verify ECM Failure Alarm. After
activation of both ECM Warning and Failure
Alarms, activate the ECM Failure Reset
Switch inside the engine control panel.
The over speed shut down set point is factory set,
programmed into the ECM, and not field adjustable.
Caution: Do not attempt to overspeed the engine to
verify overspeed shutdown.
3.5.4 Field Simulation of Pump Controller Alarms
Field simulation of pump controller alarms – Refer to
supplemental document C137716 for additional
information.


Alarm 2: Low Oil Pressure: With the engine
running, lift the low oil pressure switch.
(Note: There is no engine mounted Low Oil
Pressure switch to jumper across).

Alarm 3: High Engine Coolant Temperature:
With the engine running, lift high water
temperature switch. It may take up to 180
seconds to activate the alarm.
(Note: There is no engine mounted High
Coolant Temperature switch to jumper
across).

3.5.5 Battery Requirements
Alarm 1: Over speed Shutdown: Follow
over speed verification steps above.
All Clarke engine models require 8D batteries, as
sized per SAE J537 and NFPA20. The battery
should meet the following criteria:
Cold Cranking Amps (CCA @ 0°F): 1400
Reserve Capacity (minutes): 430
Refer to Clarke drawing C131885 (see Page 5)
for additional information on Clarke supplied
batteries.
3.6
ENGINE SPEED ADJUSTMENT
All governor and speed control functions are
programmed into each ECM at the factory. During
Start-Up Inspection, some minor speed adjustment
may be required.
Alarm 4: Over crank:
Lift and hold the OVERSPEED RESET
SWITCH for 5 seconds prior to initiating the
6 crank cycles from the fire pump controller.
Ensure that the OVERSPEED RESET
SWITCH is held for the entire duration of
each of the 6 crank attempts. Each time,
while the engine is resting for 15 seconds
between cranking attempts, release the
OVERSPEED RESET SWITCH for 3
seconds. Before the engine cranks again,
activate the OVERSPEED RESET SWITCH
and continue holding throughout the crank
attempt, releasing in between each attempt.
NEVER shut off the fuel supply to the
To adjust the speed of the engine:
A. Start the engine by following the “To Start
Engine” Procedure in this manual.
B. Let the engine warm-up. Open engine gauge
panel.
C. While observing the tachometer, lift and hold
the speed change enable switch. Toggle
speed adjustment switch up or down to
increase or reduce speed. (Refer to Figure #
23).
D. Stop engine by following “To Stop Engine”
Procedure in this manual.
E. Switch to Alternate ECM and repeat steps A
through D.
43
F. Stop engine by following “To Stop Engine”
Procedure in this manual.
G. Switch back to Primary ECM.
H. Close panel door, replace door retaining
screws.

Fuel Lines
EVERY 1 YEAR
 Air Filter
 Fuel Lift Pump Strainer
 Coolant Inhibitor
 Crankcase Vent System
o Driveshaft U-Joints
 Fuel & Oil Filters
 Heat Exchanger Electrode
 Lubricating Oil
 Mounting Isolators
 Wiring System
EVERY 2 YEARS






Figure #23
4.0 MAINTENANCE SCHEDULE
4.1 ROUTINE MAINTENANCE
NOTE: The following Routine Maintenance schedule
is based on an engine usage rate not exceeding 2
hours per month. For UL/FM engine models, also
refer to NFPA25.
Air Filter
Batteries
Belts
Coolant Hoses
Coolant
Thermostat
IMPORTANT: Set main pump controller to
“OFF” while servicing engine. Before turning the
main pump controller to the "OFF" position,
check with the maintenance and security
supervisors to verify that all the departments
concerned will be alerted of the temporary
interruption of their fire protection equipment for
normal maintenance or testing. Also, alert the
local fire department if the main pump controller
is connected by silent alarm to headquarters.
When servicing is complete, return main pump
controller selector to "Automatic" position and
the mode selector on the engine to “Automatic”
position. Advise the appropriate personnel the
engine has been returned to “Automatic”.
LEGEND:
Check
 Clean
 Replace
o Lubricate
WEEKLY

Air Filter
Battery
 Coolant Hoses
 Coolant Levels
 Cooling Water Solenoid Valve
 Exhaust System
 Fuel Tank
 General Inspection
 Governor Run-Stop Control
 Jacket Water Heater
 Lubrication Oil Level
 Operating Gauges
 Remove Water from Fuel Filter
 Run Engine
 Warning Light
EVERY 6 MONTHS


5.0 TROUBLE SHOOTING
General Troubleshooting Information
Troubleshooting engine problems can be difficult.
The engine control unit (ECM) can detect problems
internally and in the electronic control system. This
includes determining if any of the sensor input
voltages are too high or too low, if the camshaft and
crankshaft position sensor inputs are valid, and if the
unit injector solenoids are responding properly.
If the ECM detects a problem with the electronic
control system a diagnostic trouble code (DTC)
specific to the failed system will be stored in the
ECM’s memory.
 Batteries
 Battery Charging Alternator
 Belts
 Cooling Water Strainers
 Driveshaft U-Joints
44
5.1 DIAGNOSTIC TROUBLE CODES (DTC’s)
various engine systems. Not all the codes will be
present in all engine applications.
There are two types of DTC’s
 Active
 Inactive (stored)
When trouble codes appear on the PowerView
diagnostic gauge, see your engine dealer for repairs
as soon as possible.
Active DTCs indicate that the failure is occurring.
These types of failures are sometimes called “hard”
failures. They can be accessed on the diagnostic
gauge (A) on the instrument panel.
Listing of Diagnostic Trouble Codes
SPN FMI Description
28
03
Throttle #3 Input High
28
04
Throttle #3 Input Low
29
03
Throttle #2 Input High
29
04
Throttle #2 Input Low
91
03
Throttle #1 Input High
91
04
Throttle #1 Input Low
91
08
PWM Throttle Abnormal Pulse Width
91
09
Throttle Invalid
91
14
Throttle Voltage Out of Range
94
01
Fuel Supply Pressure Extremely Low
94
03
Fuel Supply Pressure Input Voltage
High
94
04
Fuel Supply Pressure Input Voltage
Inactive DTCs indicate that a failure has occurred in
the past, but is not currently occurring. This type of
“stored” DTC can be caused by an “intermittent”
failure. These could be problems such as a bad
connection or a wire intermittently shorting out.
If a sensor or wiring fails and a DTC is active for the
sensor, the ECM will use a substitute “limp home”
value in its calculation to continue engine operation.
Displaying of Diagnostic Trouble Codes (DTCs)
SPN/FMI CODES
Low
Stored and active diagnostic trouble codes
are output on the PowerView Gauge
according to the J1939 standard as a twopart code as shown on the table on the
following pages.
The first part is a Suspect Parameter Number
(SPN) followed by a Failure Mode Identifier
(FMI) code. To determine the exact failure,
both (SPN and FMI) of the code are needed.
94
Fuel Supply Pressure Moderately
High
94
18
Fuel Supply Pressure Moderately Low
97
00
Water in Fuel – Continuously
Detected
97
03
Water in Fuel Signal – Voltage High
97
04
Water in Fuel Signal – Voltage Low
97
16
Water in Fuel Detected
100
01
Engine Oil Pressure Extremely Low
100
03
Engine Oil Pressure Input Voltage
High
100
04
Engine Oil Pressure Input Voltage
Low
100
18
Engine Oil Pressure Moderately Low
102
03
Manifold Air Pressure Input Voltage
High
102
04
Manifold Air Temperature Input
Voltage Low
105
03
Manifold Air Temperature Input
Voltage High
105
04
Manifold Air Temperature Input
Voltage Low
Listing of Diagnostic Trouble Codes
105
16
Manifold Air Temperature Input
Voltage High
110
00
Engine Coolant Temperature
Extremely High
110
03
Engine Coolant Temperature Input
Voltage High
110
04
Engine Coolant Temperature Input
Voltage Low
110
16
Engine Coolant Temperature
The SPN identifies the system or the
component that has the failure; for example,
SPN 000110 indicates a failure in the engine
coolant temperature circuit.
The FMI identifies the type of failure that has
occurred; for example, FMI03 indicates value
above normal. Combining the SPN 000110
with FMI 03 yields engine coolant temperature
input voltage too high.
Always contact your Clarke service dealer for
help in correcting diagnostic trouble codes
which are displayed for your engine.
Listing of Diagnostic Trouble Codes (DTCs)
The Diagnostic Trouble Codes (DTCs) are output on
the diagnostic gauge according to J1939 standard as a
two-part code. The first part is a two to four-digit
Suspect Parameter Number (SPN) followed by a one
or two-digit Failure Mode Identifier (FMI) code.
Following is a list of SPN’s, FMI’s and a description
of the diagnostic trouble codes that can occur in the
45
16/31
111
158
174
174
611
611
620
620
627
629
636
636
636
637
637
637
01
17
03
04
03
04
03
04
01
12/13
02
08
10
02
08
07
637
651
651
652
652
653
653
654
654
655
655
656
656
970
10
05
06
05
06
06
05
06
05
06
05
05
06
02
970
31
971
1109
1110
1569
2000
31
31
31
31
13
ACP – Err
BUS – EP
Moderately High
Engine Coolant Level Low
ECM Power Down Error
Fuel Temperature Input Voltage High
Fuel Temperature Input Voltage Low
Injector Shorted to Power Source
Injector Wiring Shorted to Ground
Sensor Supply Voltage High
Sensor Supply Voltage Low
Injector Supply Voltage Problem
ECM Error
Cam Position Input Noise
Cam Position Input Missing
Cam Position Input Pattern Error
Cam Position Input Noise
Cam Position Input Missing
Crank Position/Cam Position Out of
Sync
Crank Position Input Pattern Error
Cylinder #1 EUI Circuit Open
Cylinder #1 EUI Circuit Shorted
Cylinder #2 EUI Circuit Open
Cylinder #2 EUI Circuit Shorted
Cylinder #3 EUI Circuit Open
Cylinder #3 EUI Circuit Shorted
Cylinder #4 EUI Circuit Open
Cylinder #4 EUI Circuit Shorted
Cylinder #5 EUI Circuit Open
Cylinder #5 EUI Circuit Shorted
Cylinder #6 EUI Circuit Open
Cylinder #6 EUI Circuit Shorted
Auxiliary Engine Shutdown Switch
Signal Invalid
Auxiliary Engine Shutdown Switch
Active
External Fuel De-Rate Switch Active
Engine Shutdown Warning
Engine Shutdown
Fuel De-rate
Security Violation
NOTE: Refer to wiring diagnostic earlier in this
section as a guide to connections and wires.
6.0 PARTS INFORMATION
6.1 SPARE PARTS
To ensure best operation and efficiency of all engine
components, always use genuine Clarke spare parts.
Orders should specify:
 Engine Model Number - See Engine General
 Engine Serial Number - Specification
 Part Number(s) Refer to Engine Maintenance
Parts List section 6.2 or Parts Illustration (see
Page 5).
Contact numbers for spare parts:
• www.clarkefire.com
• Phone USA: (513) 771-2200 Ext. 427 (calling
within USA)
• Phone UK: (44) 1236 429946 (calling outside USA)
• Fax USA: (513) 771-5375 (calling within USA)
• Fax UK: (44) 1236 427274 (calling outside USA)
• E-Mail USA: [email protected]
• E-Mail UK: [email protected]
6.2 ENGINE MAINTENANCE PARTS LIST
Refer to Appendix “A” at the end of this manual.
7.0 OWNER ASSISTANCE
Consult Clarke Service Dealer or Factory. Service
Dealers can be located by going to our website:
www.clarkefire.com.
8.0 WARRANTY
8.1 GENERAL WARRANTY STATEMENT
NOTE: The PowerView diagnostic gauge can have
communication problems that result in Error Codes
being shown on its LCD display window. The
following Error Codes all indicate that there is a
Diagnostic Gauge communication error with the
ECM. Contact your servicing dealer for help in
correcting these codes:
EE – Error
ACP – Err
No Addr
XXXXX - BR
No Data
The satisfactory performance of Clarke engines and
the goodwill of owners/operators of Clarke engines
are of primary concern to the Engine Manufacturer,
the Engine Service Dealer and Clarke. All provide
support of these products after final installation of the
complete fire pump and sprinkler system.
Warranty responsibility involves both Clarke and the
Caterpillar service organizations worldwide.
XXXXX – EP
No Data
The Engine Manufacturer, (Caterpillar) provides
Warranty for the basic engine components and Clarke
provides warranty on the accessories added to meet
XXXXX - BO
No Data
46
the NFPA-20 specifications and UL/FM certification
requirements.
8.2 CLARKE WARRANTY
All Clarke warranted components have warranty
duration of 24 months beginning at the Start-up date
of the fire pump system. The warranty coverage
includes replacement of the part and reasonable cost
of labor for installation. Components failed due to
improper engine installation, transportation damage,
or misuse is not covered under this warranty.
For additional warranty details, see the specific
warranty statement “Caterpillar New Engine
Warranty” in Appendix B. Contact Clarke directly if
you have any questions or require additional
information.
Clarke is not responsible for incidental or
consequential costs, damage or expenses which the
owner may incur as a result of a malfunction or
failure covered by this warranty.
8.3 CATERPILLAR WARRANTY
The Caterpillar Limited Warranty is reprinted, in its
entirety, in Appendix B. It outlines Caterpillar
Responsibilities, User Responsibilities, and Warranty
Durations.
9.0 INSTALLATION AND OPERATION DATA
(See www.clarkefire.com)
10.0 WIRING DIAGRAMS
(See www.clarkefire.com)
11.0 PARTS ILLUSTRATION DRAWINGS
(See www.clarkefire.com)
47
12.0 KEYWORD INDEX
Subject
Page
Subject
(I)
(A)
Air Filter
Alternator
9, 10, 13, 32, 33, 44, 49
11, 42, 44, 49
Installation Data
Installation Instructions
13, 15, 16
43
42
Lubricating Oil Volume
Lubricating System
(B)
Battery Cables
Battery Requirements
Belt Adjustment
Maintenance Schedule
Manual Operation
Model Number Identification
44
16-19
4
(N)
Nameplate, Engine
4
(O)
Oil Filter
10, 35, 44, 49
Oil Pressure
*
Oil Specifications/Recommendations
34-35
Operation Data
*
Out of Fuel
31
Overspeed Reset
29, 42, 44
Overspeed Verification
42
(P)
19, 20, 45-46
34, 35, 44
13-15
16, 44
Parts Illustrations
Parts Information
Powerview Gauge
Pump:
Fuel Pump
Water Pump
(E)
ECM – Engine Control Module
9, 13,
18, 19, 28, 42-46
Electrical System
8, 13, 42
Engine Gauge Panel
13, 16-19, 37, 42, 43
Engine Models
4, 6
Engine Out of Fuel
31
Engine Protective Systems (overspeed)
25, 28,
29, 33, 42, 43
Exhaust System
8, 10-13, 32, 34, 44
*
44, 46, 49
17-20, 42, 45, 46
11, 13, 32
42
(S)
Serial Number
Shutdown Systems
Soft Start
Speed Adjustment
Storage
4, 46
18-20, 28, 29, 42, 43
16, 17
13, 43, 44
10-12, 30
(T)
Technical Data
(F)
Fuel Filter
Fuel Specifications
Fuel System Operation
Bleeding
Priming Pump
35
12, 35
(M)
Capacities
12, 35, 36, 43
Coolant Recommendations
11, 12, 16,
37-37, 42
Cooling System
Coolant System Capacity
36
Cooling Water Supply Loop
12, 16, 37-40
Cooling Water Flow Requirements
*
Filling Procedure
37
Heat Exchanger
9, 12, 16, 35, 37,
38, 40, 44, 49
Inhibitors
36, 37, 44
Maintenance
11, 12, 37, 44
Water
36
Crankcase Ventilation
11, 33, 44
(D)
Diagnostic Trouble Codes
Dipstick, Oil Level
Driveshaft Alignment
Driveshaft Maintenance
*
10-15
(L)
(C)
11, 13, 29-32, 44, 49
13, 29
(W)
Warranty
Wiring Diagram:
DC System
AC Heater System
30-32
11, 30, 31
(H)
Heater, Engine
Page
* See www.clarkefire.com
9, 13, 36, 40, 42, 44
48
*
13, 46
*
*
Appendix “A”
C18 MODELS PARTS MATRIX
Clarke Engine Models
C18H0-UFAC10
C18H0-UFAC18
C18H0-UFAC20
C18H0-UFAC28
Part Description
C18H0-UFAD50
C18H0-UFAD58
C18H0-UFAD68
C18H0-UFAD70
C18H0-UFAD78
Part Number (standard items only, optional items not shown)
1R1808
3261641
1R0749
C03244
1693345
C051389
3383454
Oil Filter
Fuel Filter (Primary)
Fuel Filter (Secondary)
Air Filter
Alternator (24V)
Heat Exchanger
Starter Motor (24V)
Engine Control
Module
Turbocharger
Thermostat
Fuel Injector
C18H0-UFAA78
C18H0-UFAD10
C18H0-UFAD18
C18H0-UFAD20
C18H0-UFAD28
C18H0-UFAD30
C18H0-UFAD38
C18H0-UFAD40
C18H0-UFAD48
4787932
3595394, 3595395
3595390, 3595391
2477133
2768307
2915911
49
Appendix “B”
50
51
CLARKE FIRE PUMP DRIVERS
EPA NSPS TIER 3 ENGINE MODELS
HSC APPLICATIONS
�
[±J - MOUNTING FACE OF FLYWHEEL
� - ENGINE CRANKSHAFT HORIZONTAL
CENTERLINE
� - ENGINE CRANKSHAFT VERTICAL
CENTERLINE
I -D-I- PUMP SHAFT HORIZONTAL CENTERLINE
C18H0-UFAD10,18, 20, 28, 30,
38, 40,48, so··. 68, 10··
REF.
c- !cq===•�=====,$+::::;:; ==,�=========::::�117
l-----
�
I
/,,,,,---- __ _l__l__ _ +!
(
"----------- '
NON-LISTED DRIVESHAFTS
ENGINE MODEL
A
25 0.
REF.
DRIVESHAFT MODEL
I
I
SC2160A
' ' -l
I
I
I
I
B ___________ B _____
2
X
2
X
50
�
1·
1 . 5
=i-----m-
------------,-;ci
i
1
---------------
!
I
I
6#-�
------�-----------�----------�-'-i
---FOR OPTIONAL
BASE MOUNTED
CONTROLLER
C18H0-UFAD50*,58,70*,78,42***
SC2390A
*1900RPM ONLY, **2100RPM ONLY
***PLD (-D) Option Available for This Model Only
01.0 X 2.0 SLOT
6PLACES
TOP AND BOTTOM
FLANGES
5
o_ o
o REF .
JJ
48.
Horizontal Split Case
ITEM
NO.
0
0
0
0
0
NOTES:
1. GENERAL TOLERANCE: UNLESS OTHERWISE
SPECIFIED, ALL DIMENSIONS ARE IN INCHES AND
VARY 0.38".
2. THE DRIVE SHAFT IS DESIGNED TO OPERATE AT A
2' ANGLE WITH THE INPUT AND OUTPUT SHAFTS IN
PARALLEL. THE ENGINE CRANKSHAFT IS TO BE
SET WITH A PARALLEL OFFSET OF 0.45 ± 0.15
INCHES VERTICALLY ABOVE THE PUMP SHAFT AND
0.00" ± 0.15 INCH PARALLEL OFFSET HORIZONTALLY
RIGHT OR LEFT OF THE PUMP SHAFT. REFER TO
THE CERTIFIED DRIVESHAFT INSTRUCTIONS
MANUAL FOR ALIGNMENT INSTRUCTIONS.
3. BASE MUST BE COMPLETELY FILLED WITH GROUT
PER NFPA 20.
4. PUMP IS CW (CLOCKWISE) ROTATION WHEN
VIEWED FROM THE COUPLING END.
5. SUCTION AND DISCHARGE FLANGES DRILLED PER
ANSI B16.1 (IF APPLICABLE).
6. RAW WATER OUTLET SIZE VARIES BASED UPON
SITE CONDITIONS. DEFAULT SIZE: 1-1/2" NPT
7. CAUTION: ALL PLUMBING MUST BE SUPPORTED
AND/OR ISOLATED SO THAT NO WEIGHT OR
STRESS IS APPLIED TO ANY ENGINE COMPONENT.
8. CAUTION: SPREADER BARS REQUIRED TO MOVE
PACKAGE. DAMAGE DUE TO IMPROPER HANDLING
IS NOT WARRANTABLE.
DESCRIPTION
CONNECTION SIZE
EXHAUST OUTLET
CONNECTION
8 " 1 50# FLG.
RAW WATER OUTLET
SEE NOTE6.
FUEL SUPPLY
CONNECTION
/3 4" NPTF
FUEL RETURN
CONNECTION
1/2" NPTF
HEATER JUNCTION
OX
B
VOLTAGE REQUIREMENTS:
AC CONNECTION
HEATER 3 0
5 0 WATTS
STD-230 VAC ±5%-10%
FUEL PUMP
CENTERLINE
0. 45
SEE
NOTE2
L_-t-'i::::::3�
s
.,...____..,...______-_____________......
,____
JL..,_..J.
______
w
10.0
REF.
•
�
�
LIFTING
HOLES
4X
.8
HEATER JUNCTION
BOX LOCATED ON
BACK SIDE OF
ENGINE VIEW
E
_ __L�
z
'����
SUCTION
DISCHARGE
I
-I
APPROVED DOCUMfNT
5
BY: GERARDO PINA jJ,JjP""
DATE: 13-MAY-2020 "'1
PROJECT:153200083
24.8
26.8 f
RUHRPUMPEN
Certified for·
PUMP
TYPE
zw
zw
ALL VIEWS 3rd ANGLE PROJECTION
DIMENSIONS
PUMP SIZE
SUCT.
12
14
-@)--E3-
DISCH.
10
10
CASE
BORE
20
24
A
128.0
138.0
B
59.0
64.0
H
34.0
38.0
E
15.1
23.7
M
19.7
20.9
w
24.9
26.3
CP
44.6
47.3
D
21.7
26.8
VY
23.6
27.6
X
21.7
25.6
s
13.0
15.7
z
13.0
15.7
D Approval
D Construction
By·
Date·
Listed·
Project:
Capacity:
Engine Supplier:
Customer:
Total Pressure:
Engine Model:
Item/ P.O. No.:
Pump Speed:
Engine Preheater Voltage:
Quote No.:
Power:
Pump Serial No.:
Pump Model:
Rotation:
CLOCKWISE (Right Hand)
□ UL
□ FM
CLARKE
SO No.:
C137994 RevD
12MAY20
C18H0 MODELS
UFAD18
UFAD10
UFAD28
UFAD28
R
UFAD30
UFAD48
UFAD40
UFAD58
UFAD50
UFAD68
UFAD78
UFAD70
UFAC18
UFAC10
UFAC28
UFAC20
UL/FM - cUL APPROVED RATINGS BHP/kW
C18H0
MODEL
RATED SPEED
1470
1760
460
UFAD18
510
380
542
404
UFAD38
600
447
UFAD48
650
485
UFAD58
687
512
UFAD68
700
392
525
392
429
575
429
447
600
447
485
650
485
700
EPA Tier 3 Certified
EPA Tier 3 Certified
All Models are available for export
755
800
EPA Tier 3 Certified
522
700
522
700
522
755
563
755
563
800
596.5
800
596.5
EPA Tier 2 Certified
EPA Tier 2 Certified
596.5
UFAC20
EPA Tier 3 Certified
EPA Tier 2 Certified
563
UFAC10
UFAC28
EPA Tier 3 Certified
Non-Emissionized
UFAD70
UFAC18
EPA Tier 3 Certified
EPA Tier 3 Certified
522
UFAD78
EPA Tier 3 Certified
EPA Tier 3 Certified
650
UFAD50
364
EPA Tier 3 Certified
600
UFAD40
488
EPA Tier 3 Certified
575
UFAD30
364
EPA Tier 3 Certified
525
UFAD20
EMISSIONS
EPA Tier 3 Certified
488
UFAD28
2100
343
UFAD10
UFAA78
1900
EPA Tier 2 Certified
ENGINE SPECIFICATIONS
Number of Cylinders
6
Aspiration
TRWA
Rotation*
CW
Overall Dimensions - in. (mm)
66.1(1678) H X 79.6(2022) L X 45.2(1147) W
Crankshaft Centerline Height - in. (mm)
17.0 (432)
Weight - lb (kg)
4100 (1860)
Compression Ratio
16.3:1
Displacement - cu. in. (I)
1104 (18.1)
Engine Type
Abbreviations: TRWA - Turbocharged and Raw Water Aftercooled
*Rotation viewed from Heat Exchanger / Front of engine
CERTIFIED POWER RATING
•
Each engine is factory tested to verify power and performance
4 Stroke Cycle - Inline Construction
CW - Clockwise
ENGINE RATINGS BASELINES
•
•
•
•
Engines are to be used for stationary emergency standby fire pump
service only. Engines are to be tested in accordance with NFPA 25.
Engines are rated at standard SAE conditions of 29.61 in. (752.1
mm) 77°F (25°C) inlet air temperature [approximates 300 ft. (91.4
m) above sea level] by the testing laboratory (see SAE Standard J
1349).
A deduction of 3 percent from engine horsepower rating at standard
SAE conditions shall be made for diesel engines for each 1000 ft.
(305 m) altitude above 300 ft. (91.4 m)
A deduction of 1 percent from engine horsepower rating as corrected
to standard SAE conditions shall be made for diesel engines for
every 10°F (5.6°C) above 77°F (25°C) ambient temperature.
C18H0 MODELS
UFAD18
UFAD10
UFAD28
UFAD28
R
ENGINE EQUIPMENT
UFAD30
UFAD48
UFAD40
UFAD58
UFAD50
UFAD68
UFAD78
UFAD70
UFAC18
UFAC10
UFAC28
UFAC20
EQUIPMENT
STANDARD
OPTIONAL
Air Cleaner with Air Differential
Gauge
Direct Mounted, Washable, Indoor Service with Drip Shield
Disposable, Drip Proof, Indoor Service Outdoor Type,
Single or Two Stage
Alarm
Overspeed Alarm & Shutdown, Low Oil Pressure, Low & High Coolant
Temperature, Low Raw Water Flow, High Raw Water Temperature, Alternate
ECM Warning, Fuel Injection Malfunction, ECM Warning and Failure with
Automatic Switching
Low Coolant Level, Low Oil Level, Oil Filter
Differenetial Pressure, Fuel Filter Differential
Pressure, Air Filter Restriction
Alternator
24V-DC, 50 Amps with V-Belt and Guard
Coupling
Bare Flywheel
Driveshaft and Guard
Crankcase Ventilation
Crankcase Breather
Engine Heater
230V-AC, 3500 Watt
Exhaust Flex Connection
SS Flex. 150# ANSI Flanged Connection. 8”
Exhaust Protection
Metal Guard on Manifold and Turbocharges
Flywheel Housing
SAE #1
Flywheel Power Take Off
14” SAE Industrial Flywheel Connection
Fuel Connections
Fire Resistent Supply and Return Lines
Fuel Filter
Primary Filter / Water Separator with Priming Pump, Secondary Filter
Fuel Injection System
Unit Injector
Governor, Speed
Electronic, Dual Electronic Engine Control Modules
Heat Exchanger
Shell and Tube Type, 60 PSI (4 Bar), NPT (F) Connections - Sea Water
Compatible
Instrument Panel
NEMA Type 2, Powder Coated Steel Construction, Multimeter to Display
English and Metric, Tachometer, Hour meter, Water Temperature, Oil
Pressure, and Dual Voltmeters, Front Opening, Soft Start for Commissioning
Junction Box
Integral with Instrument Panel; For DC Wiring Interconnection to Engine
Controller
Lube Oil Cooler
Jacket Water Cooled, Shell and Tube Type
Lube Oil Filter
Full Flow, Dual Element
Lube Oil Pump
Gear Driven, Gear Type
Manual Start Control
Dual Manual Start Contactors & On Instrument Panel with Control Position
Warning Light
Overspeed Control
Electronic, Factory Set
Raw Water Cooling Loop w/ Alarms
Galvanized
Raw Water Solenoid Operation
Automatic from Fire Pump Controller and from Engine Instrument Panel (for
Horizontal Fire Pump Applications)
Run - Stop Control
On Instrument Panel with Control Position Warning Light
Starters
One (1) 24V-DC
Throttle Control
Adjustable Speed Control by Increase/Decrease Button, Tamper Proof
Adjustable Speed Control
Water Pump
Centrifugal Type, Gear Driven
SS Flex. 150# ANSI Flanged Connection. 10”
SS, Braided, cUL Listed, Supply and Return Lines
316 Stainless Steel NEMA 4X/IP66
Seawater, All 316 SS, High Pressure
Abbreviations: DC - Direct Current, AC - Alternating Current, SAE - Society of Automotive Engineers, BSP(F) - British Standard Pipe Thread (Female), SS - Stainless Steel
MODEL NOMENCLATURE (11 Digit Models)
C18H0-UFAD78
Base Engine
18 Liter
Heat Exchanger Cooled
Non-Hazardous Environment
Rating Code
EPA Tier 3 Certified (“C” = EPA Tier 2 Certified, “A” = Non-Emissionized)
Built in USA
UL Listed and FM Approved
Specifications and information contained in this brochure is subject to change without notice.
R
100 Progress Place, Cincinnati, OH 45246
United States of America
Tel +1-513-475-3473 Fax +1-513-771-8930
C137765 RevB
16JUL19
Grange Works, Lomand Rd, Coatbridge, ML5-2NN
United Kingdom
Tel +44-1236-429946 Fax +44-1236-427274
www.clarkefire.com
4
3
2
1
D
D
C
C
B
B
CONTROLLED DRAWING
THIS IS A REGISTERED PART WITH A THIRD PARTY
AGENCY FOR USE ON A PRODUCT. NO SUBSTITUTIONS
ARE ALLOWED. CONSULT ENGINEERING PRIOR TO AND
REGARDING ANY CHANGE.
REV
A
DESCRIPTION
ISSUED ENGINEERING DRAWING
THIS DRAWING AND THE
INFORMATION HEREON ARE
OUR PROPERTY AND MAY BE
USED BY OTHERS ONLY AS
AUTHORIZED BY US
UNPUBLISHED--ALL RIGHTS
RESERVED UNDER THE
COPYRIGHT LAWS
UNLESS NOTED OTHERWISE,
TOLERANCING GUIDELINES
WILL BE AS SHOWN BELOW
DECIMAL
X.
X.X
X.XX
X.XXX
mm
1.5
0.8
0.3
inch
0.06
0.03
0.01
4
APVD
DATE
05APR18
NO
CONTROLLED
DRAWING
DRWN
DATE
ENGR
MJDEMBKOWSKI
NAME
WIRING DIAGRAM, ENGINE
SENSORS, C18
4/5/2018
MJDEMBKOWSKI
MATL
PART NO.
ASSM
ANGULAR: 0.5°
DWN
MJD
®
YES
MACHINE TOLERANCE
A
ECN#
5098
CAT18
SIMILAR TO
ORIGINAL PART
3
UNITS
SCALE
NTS
REV
C072754
A
PAGE
MM [INCH]
2
1
OF
1
1
A
4
3
1
END INLET, END OUTLET
D
C
2
P/N
C06540
C06541
C06542
INDUSTRIAL
A
B
2.00
6
2.50
8
3.00
8
D
24.00
24.00
25.00
Wgt#
15
22
26
P/N
C06528
C06529
C06530
P/N
C06544
C06545
C06546
C06547
C06548
INDUSTRIAL
A
B
4.00
10
5.00
12
6.00
12
8.00
18
10.00
22
D
32.00
44.00
44.00
56.00
72.00
Wgt#
45
67
74
142
217
P/N
C06532
C06533
C06534
C06535
C06536
B
2"‐3.5" NPT CONNECTIONS
RESIDENTIAL
A
B
D
Wgt#
P/N
2.00
6
30.00
20
C06514
2.50
8
30.00
28
C06515
3.00
8
31.00
32
C06516
4"‐12" 150# ANSI FLANGE
RESIDENTIAL
P/N
A
B
D
Wgt#
C06518
4.00
10
44.00
61
C06519
5.00
12
56.00
91
C06520
6.00
12
56.00
98
C06521
8.00
18
68.00
177
10.00
22
84.00
284
C06522
D
CRITICAL
A
B
2.00
6
2.50
8
3.00
8
D
42.00
42.00
43.00
Wgt#
31
42
45
CRITICAL
A
B
4.00
10
5.00
12
6.00
12
8.00
18
10.00
22
D
Wgt#
56.00
83
68.00
117
68.00
131
92.00
235
108.00 342
P/N
C06716
C06717
C06718
HOSPITAL
A
B
2.00
10
2.50
12
3.00
12
D
44.00
46.00
46.00
P/N
C06720
C06721
C06722
C06723
C06724
HOSPITAL
A
B
4.00
14
5.00
18
6.00
18
8.00
26
10.00
30
D
Wgt#
60.00
111
68.00
176
68.00
184
96.00
394
110.00 696
Wgt#
54
69
70
C
B
DIMENSIONS ARE IN INCHES
NOTES:
1. DUAL SHELL DESIGN TO ELIMINATE SHELL RADIATED NOISE AND INCREASE DURABILITY.
2. CARBON STEEL CONSTRUCTION.
3. COATED WITH SATIN BLACK PAINT RATED TO 1200°F
4. CONNNECTIONS:
-MALE NPT ON 3.5" AND SMALLER
-125/150# ANSI FLANGES
5. EQUIPPED WITH PORT PLUGGED DRAIN.
6. ALL WELDED CONSTRUCTION.
THIS DRAWING AND THE
INFORMATION HEREON ARE OUR
PROPERTY AND MAY BE USED BY
OTHERS ONLY AS AUTHORIZED BY
US. UNPUBLISHED--ALL RIGHTS
RESERVED UNDER THE
COPYRIGHT LAWS
A
4
REV
DESCRIPTION
E
ADDED INDUSTRIAL SILENCERS
ADDED NPT VIEW
F
REMOVED 3.5" & 12" AND UPDATED MATERIAL
G
REMOVED DRAIN FROM OUTLET SIDE
H
UPDATED PAGE 2 FIGURES
3
ECN#
4407
3862
3862
3862
3862
DWN
DTH
JGV
JGV
JGV
CRD
APVD
JCA
JCA
JCA
JCA
JCA
2
DATE
25FEB16
21APR16
28APR16
06OCT16
29OCT16
MACHINE TOLERANCE
inch
DECIMAL mm
X.
 1.5
X.X
0.06
 0.8
X.XX
0.03
 0.3
0.01
X.XXX
 0.025
X.XXXX
0.001
ANGULAR: 0.5
FABRICATION TOLERANCE
DECIMAL mm
inch
3
X.
X.X
0.12
1.5
X.XX
0.06
ANGULAR: 1.0
YES
NO
CONTROLLED
DRAWING
DRWN
DMPOTTER
DATE
7/22/1992
ENGR
DMPOTTER
Fire Protection Products, Inc.
NAME
SILENCER, EXHAUST (END INLET, A
END OUTLET) & (SIDE INLET, END
OUTLET)
MATERIAL
PART NO.
ORIGINAL USAGE
SIMILAR TO
N/A
UNITS
SCALE
NTS
REV
D451
ASSEMBLY
H
PAGE
MM [INCH]
1
1
OF
2
4
3
D
2"‐3.5" NPT CONNECTIONS
P/N
C06580
C06581
C06582
INDUSTRIAL
A
B
2.00
6
2.50
8
3.00
8
P/N
C06584
C06585
C06586
C06587
C06588
INDUSTRIAL
A
B
4.00
10
5.00
12
6.00
12
8.00
18
10.00
22
B
A
1
SIDE INLET, END OUTLET
D
C
2
D
22.00
22.00
22.00
D
29.50
41.60
41.60
54.50
69.00
Wgt#
15
22
26
Wgt#
45
67
74
142
217
P/N
C06568
C06569
C06570
P/N
C06572
C06573
C06574
C06575
C06576
RESIDENTIAL
P/N
A
B
D
Wgt#
C06554
2.00
6
28.00
20
C06555
2.50
8
28.50
28
C06556
3.00
8
29.00
32
4"‐12" 150# ANSI FLANGE
RESIDENTIAL
P/N
A
B
D
Wgt#
4.00
10
41.50
61
C06558
5.00
12
54.00
91
C06559
6.00
12
54.00
98
C06560
8.00
18
66.50
177
C06561
10.00
22
81.00
284
C06562
CRITICAL
A
B
2.00
6
2.50
8
3.00
8
CRITICAL
A
B
4.00
10
5.00
12
6.00
12
8.00
18
10.00
22
D
39.75
39.88
40.62
Wgt#
31
42
45
D
Wgt#
53.50
83
65.62
117
65.62
131
90.50
235
105.00 342
P/N
C06730
C06731
C06732
HOSPITAL
A
B
2.00
10
2.50
12
3.00
12
P/N
C06734
C06735
C06736
C06737
C06738
HOSPITAL
A
B
4.00
14
5.00
18
6.00
18
8.00
26
10.00
30
D
41.50
42.50
42.50
Wgt#
54
69
70
D
B
END OUTLET
SIDE INLET
A
DRAIN
D
Wgt#
56.50
111
66.50
176
66.50
184
93.50
394
108.00 696
C
B
DIMENSIONS ARE IN INCHES
NOTES:
1. DUAL SHELL DESIGN TO ELIMINATE SHELL RADIATED NOISE AND INCREASE DURABILITY.
2. CARBON STEEL CONSTRUCTION.
3. COATED WITH SATIN BLACK PAINT RATED TO 1200°F
4. CONNNECTIONS:
-MALE NPT ON 3.5" AND SMALLER
-125/150# ANSI FLANGES
5. EQUIPPED WITH PORT PLUGGED DRAIN.
6. ALL WELDED CONSTRUCTION.
4
3
THIS DRAWING AND THE
INFORMATION HEREON ARE OUR
PROPERTY AND MAY BE USED BY
OTHERS ONLY AS AUTHORIZED BY
US. UNPUBLISHED--ALL RIGHTS
RESERVED UNDER THE
COPYRIGHT LAWS
MACHINE TOLERANCE
inch
DECIMAL mm
 1.5
X.
X.X
0.06
 0.8
0.03
X.XX
 0.3
0.01
 0.025
X.XXX
X.XXXX
0.001
ANGULAR: 0.5
FABRICATION TOLERANCE
inch
DECIMAL mm
3
X.
X.X
0.12
1.5
0.06
X.XX
ANGULAR: 1.0
2
YES
NO
CONTROLLED
DRAWING
DRWN
DMPOTTER
DATE
7/22/1992
ENGR
DMPOTTER
Fire Protection Products, Inc.
NAME
SILENCER, EXHAUST (END INLET, A
END OUTLET) & (SIDE INLET, END
OUTLET)
MATERIAL
Welded Steel Mild
PART NO.
ORIGINAL USAGE
SIMILAR TO
N/A
UNITS
SCALE
NTS
REV
D451
ASSEMBLY
H
PAGE
MM [INCH]
1
2
OF
2
INSTALLATION AND MAINTENANCE MANUAL FOR
DIESEL ENGINE FIRE PUMP CONTROLLERS
MODEL GPD
1
Table of Contents
1. Introduction
2. Installation
3. Main Features
4. Home
5. Alarms
6. Configuration
7. History
8. Service
9. Download Manuals
10. Language
11. Technical Documents
2
GPDV2-Manual-EN v2.2.0.0
Table of Contents
Introduction...................................................................................................................................................................... 5
Types of Diesel Engine Fire Pump Controllers .......................................................................................................... 5
Methods of Starting/Stopping ..................................................................................................................................... 5
Installation ....................................................................................................................................................................... 7
FCC Regulations and Radio Standards Specification (RSS) Rules .......................................................................... 7
Location ...................................................................................................................................................................... 7
Mounting .................................................................................................................................................................... 8
Storage ....................................................................................................................................................................... 8
Wiring and Connections ............................................................................................................................................. 8
Water Connections ..................................................................................................................................................... 8
Electrical Wiring ......................................................................................................................................................... 8
Electrical Connections................................................................................................................................................ 8
Energy Consumption.................................................................................................................................................. 9
Incoming Power Connections .................................................................................................................................... 9
Circuit protection ........................................................................................................................................................ 9
Terminal Strip Descriptions ......................................................................................................................................10
Quick Start-Up Guide ...............................................................................................................................................11
Main Features ...............................................................................................................................................................19
The ViZiTouch ..........................................................................................................................................................19
Alarm Bell .................................................................................................................................................................19
First Setup ................................................................................................................................................................19
ViZiTouch: Manual Rebooting Method .....................................................................................................................20
Pressure Transducer Test........................................................................................................................................20
Home .............................................................................................................................................................................21
Home (Menu) ...........................................................................................................................................................21
Screen Saver ...........................................................................................................................................................23
Alarms ...........................................................................................................................................................................24
Alarms (Menu) ..........................................................................................................................................................24
Configuration .................................................................................................................................................................28
Config (Menu) ..........................................................................................................................................................28
NumPad Page ..........................................................................................................................................................29
Date and Time Page ................................................................................................................................................29
User Login Page / KeyPad Page .............................................................................................................................30
Advanced Configuration Page .................................................................................................................................31
Control Timers ..........................................................................................................................................................31
Alarms ......................................................................................................................................................................32
Chargers and Batteries ............................................................................................................................................33
Starter Configuration ................................................................................................................................................34
Sensor Selection ......................................................................................................................................................34
Outputs .....................................................................................................................................................................36
3
Update Program Page .............................................................................................................................................37
Factory Settings .......................................................................................................................................................38
Interlock Lockout ......................................................................................................................................................38
Inputs........................................................................................................................................................................39
I/O Card Info .............................................................................................................................................................39
Network ....................................................................................................................................................................40
Reboot ViZiTouch ....................................................................................................................................................40
History ...........................................................................................................................................................................41
History (Menu) ..........................................................................................................................................................41
Events Page .............................................................................................................................................................42
Pressure Curves ......................................................................................................................................................42
Power Curves ...........................................................................................................................................................43
Saved Logs ..............................................................................................................................................................44
Pump Curves ...........................................................................................................................................................45
Statistic .....................................................................................................................................................................46
All Time Statistics .....................................................................................................................................................46
First Service Statistics ..............................................................................................................................................47
Last Service Statistics ..............................................................................................................................................48
Download .................................................................................................................................................................48
Service ..........................................................................................................................................................................49
Service .....................................................................................................................................................................49
Download Manuals ........................................................................................................................................................50
Language ......................................................................................................................................................................50
Technical Documents ....................................................................................................................................................50
4
Introduction
Diesel engine fire pump controllers are designed to automatically start a diesel engine driven fire pump upon
detection of a pressure drop in the fire protection system. A diesel engine fire pump controller provides automatic
& manual starting and stopping. An automatic start is controlled by a pressure transducer or by remote automatic
devices such as a deluge valve. A manual start is controlled by remote manual button or by controller pushbutton.
The automatic shutdown option provides a 30-minute automatic stop after automatic start once all starting causes
have returned to normal. The diesel engine fire pump controller includes two battery chargers to ensure the
engine batteries are continuously charged.
Types of Diesel Engine Fire Pump Controllers
FIRE PUMP CATALOG NUMBER
MODEL No. EXAMPLE: GPD-12-120
Model Prefix: GPD, GPDFM
Battery Voltage: 12=12v, 24=24v
Incoming Voltage: 120=110/120V 50/60Hz, 220=208/240V 50/60Hz
Methods of Starting/Stopping
The controllers are available as combination automatic / non-automatic with provision for manual or automatic
shutdown (an automatic shutdown is only possible after an automatic start).
METHODS OF STARTING
AUTOMATIC START
The controller will start automatically on low pressure detection by the pressure sensor when the pressure drops
below the cut-in threshold.
MANUAL START
The engine can be started by pressing the CRANK 1 or and/or CRANK 2 push button, regardless of the system
pressure, when the Main Selector switch is in the HAND position. The Fuel Solenoid Valve will open as soon as a
CRANK button is pressed and will remain in this state.
REMOTE MANUAL START
The engine can be started from a remote location by momentarily closing a contact of a manual push button.
REMOTE AUTOMATIC START, DELUGE VALVE START
The engine can be started from a remote location by momentarily opening a contact connected to an automatic
device. The controller must be in automatic mode.
SEQUENTIAL START
In case of a multiple pump application, it may be necessary to delay the starting of each motor when there is a
water pressure drop to prevent simultaneous starting of all motors.
FLOW START, HIGH ZONE START
The pump can be started by opening/closing a contact on the FLOW/ZONE START/STOP input.
WEEKLY START
The engine can be started (and stopped) automatically at the preprogrammed time.
TEST START
The motor can be started manually by pressing the run test button.
5
METHODS OF STOPPING
MANUAL STOP
Manual stop is done by pressing the STOP push button. Note that pressing the stop push button will stop the
engine only if all starting causes have disappeared.
AUTOMATIC STOP
The automatic stop is possible only after an automatic start and this function has been activated. When this
function is Enabled, the motor is automatically stopped 30 minutes (adjustable) after the restoration of the
pressure (above the cut-out threshold) given that no other run cause is present.
FLOW STOP, HIGH ZONE STOP
If the controller has been started by the FLOW/ZONE START/STOP input and the signal has returned to normal,
the motor will be stopped given that no other run cause is present.
EMERGENCY STOP
The emergency stop is always possible in any running condition and is done by positioning the main selector
-switch to the OFF position.
6
Installation
This diesel controller is UL listed and FM certified. The controller is built in accordance with the latest edition of the
National Fire Protection Association standard for the Installation of Centrifugal Fire Pumps, NFPA No.20
(Centrifugal Fire Pumps 2013 Edition). The controller is intended to be installed in accordance to NFPA 20-2013
and
in the USA National Electrical Code NFPA 70
In Canada Canadian Electrical Code, Part 1
Others * Local Electrical Codes *
* Only American and Canadian applicable codes have been considered during the design of the controllers and the
selection of components.
Except in some cases, the controller is also seismic approved and has been tested in accordance with the ICC-ES
AC156, IBC 2015 & CBC 2016 standards. Proper installation, anchoring and mounting is required to validate this
compliance report. Refer to this manual and drawings to determine the seismic mounting requirements and location
of the center of gravity (you may need to contact factory). The equipment manufacturer is not responsible for the
specification and performance of anchorage systems. The structural engineer of record on the project shall be
responsible for anchorage details. The equipment installation contractor shall be responsible for ensuring the
requirements specified by the structural engineer of record are satisfied. If detailed seismic installation calculations
are required, please contact the manufacturer for the performance of this work.
FCC Regulations and Radio Standards Specification (RSS) Rules
To comply with FCC and Industry Canada RF exposure compliance requirements, a separation distance of at least
20 cm must be maintained between the antenna of this device and all nearby persons. This device must not be colocated or operating in conjunction with any other antenna or transmitter.
This device complies with Industry Canada licence-exempt RSS standard(s). Operation is subject to the following
two conditions: (1) this device may not cause interference, and (2) this device must accept any interference,
including interference that may cause undesired operation of the device.
This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This
device may not cause harmful interference, and (2) this device must accept any interference received, including
interference that may cause undesired operation.
Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to
part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful
interference in which case the user will be required to correct the interference at his own expense.
“Changes or modifications not expressly approved by the party responsible for compliance could void the user's
authority to operate the equipment.”
Location
The controller shall be located as close as practical to the engine/motor it controls and shall be within sight of the
engine/motor. The controller shall be located or protected such that it will not be damaged by water escaping from
pump or pump connections. Current carrying parts of the controller shall be not less than 12 in. (305 mm) above the
floor level.
7
Working clearances around controller shall comply with NFPA 70, National Electrical Code, Article 110 or C22.1,
Canadian Electrical Code, Article 26.302 or other local codes.
The controller is suitable for use in locations subject to a moderate degree of moisture, such as a damp basement.
The pump room ambient temperature shall be between 39°F (4°C) and 104°F (40°C) (If a temperature option is
included, see the rating label for maximum temperature).
The standard controller enclosure is rated NEMA 2. It is the installer's responsibility to insure that either the
standard enclosure meets the ambient conditions or that an enclosure with an appropriate rating has been
provided. Controllers must be installed inside a building and they are not designed for outside environment. The
paint color may change if the controller is exposed to ultraviolet rays for a long period of time.
Mounting
The fire pump controller shall be mounted in a substantial manner on a single incombustible supporting structure.
Wall mounted controllers shall be attached to the structure or wall using all four (4) mounting ears provided on the
controller with hardware designed to support the weight of the controller at a height not less than 12 in. (305 mm)
above floor level. Floor mounted controllers shall be attached to the floor using all holes provided on the mounting
feet with hardware designed to support the weight of the controller. The mounting feet provide the necessary 12 in.
(305 mm) clearance for current carrying parts. For seismic applications, the mounting arrangement should be rigid
wall and base only. The structural engineer of record on the project shall be responsible for anchorage details.
Storage
If the controller is not installed and energized immediately, Tornatech recommend following the instructions from the
chapter 3 of the NEMA ICS 15 standard.
Wiring and Connections
Water Connections
The controller must be connected to the pipe system according to the latest edition of NFPA20 and also to a drain
pipe. The water connections are on the left side of the controller. The connection to the system pressure is a Male
½ NPT. If a drain is present, the connection to the drain is a tapered connection for plastic tubing.
Electrical Wiring
The electrical wiring between the power source and the diesel engine fire pump controller shall meet the NFPA 20,
Chapter 12.3.5.1, 12.3.5.2 and 12.2.5.3, NFPA 70 National Electrical Code Article 695 or C22.1 Canadian Electrical
Code, Section 32-200 or other local codes.
Electrical Connections
A licensed electrician must supervise the electrical connections. The dimension drawings show the area suitable for
incoming power and motor connections. No other location shall be used. Only watertight hub fittings shall be used
when entering the cabinet to preserve the NEMA rating of the cabinet. The installer is responsible for adequate
protection of the fire pump controller components against metallic debris or drilling chips. Failure to do so may
cause injuries to personnel, damage the controller and subsequently void warranty.
8
Energy Consumption
Diesel Controller with boost charger
Model / State
12VDC / @
No charge
12VDC / @
Full charge*
24VDC / @
No charge
24VDC / @
Full charge**
120VAC
220/240VAC
1.0A
1.0A
6A
4A
1.0A
0.5A
9A
6A
VDC Output
13.8V
27.6V
*12 amps through each battery
**10 amps through each battery
Incoming Power Connections
Diesel engine driven fire pump controllers shall be powered by a dedicated source protected by a fuse or circuit
breaker. Verify the label on the cabinet to select the correct protection. Always follow this procedure when
connecting or disconnecting the controller: Connect both batteries before connecting the AC power. Disconnect the
AC power before disconnecting the batteries. Disconnecting the batteries while the AC is connected may result in
severe damage to the controller electronic boards.
Circuit protection
CB1 protects battery charger 1 and CB2 protects battery charger 2. CB3 protects the control circuit from battery 1
and CB4 protects the control circuit from battery 2.
Always follow this procedure when connecting or disconnecting the controller: Connect both batteries before
connecting the AC power. Disconnect the AC power before disconnecting the batteries.
9
Terminal Strip Descriptions
A-F : Alarm Output Terminals
(DPDT Relay, 11/21:Common, 12/22:Normally Closed,
14/24:Normally Open):
A: Controller Trouble (Fail safe)
B: Engine Run
C: Main SS in HAND/OFF position
D: Engine Trouble
E: Pump Room Alarm
F: Optional Output 1
G-T : Field Input Terminal
(Dry Contact Only: Voltage Free):
G: Low Fuel Level (NO)
H: Remote Automatic Start (NC)
I: Deluge Valve Start (NC)
J: Fuel Tank Leak (NO)
K: High Fuel Level (NO)
L: Engine RPM Magnetic Pickup
M: ECMS Elec. Ctrl. Switch in Alternate Position
N: FIM Fuel Injection Malfunction
O: ECMW Elec. Ctrl. Warning
P: ECMF Elec. Ctrl. Fault
Q: PLD Low Suction Pressure
R: High Raw Water Temperature
S: Low Raw Water Flow
T: LET Low Engine Temperature
U : Engine Terminals :
The terminals are numbered according to the standard:
1 - FS : Fuel Solenoid Valve
(ETR - Energized To Run)
2 - ER : Engine Run contact
3 - OS : Engine Overspeed contact
4 - OP : Engine Oil Pressure contact
5 - WT : Engine Coolant Thermostat contact
6 - B1 : Battery #1 positive
8 - B2 : Battery #2 positive
9 - C1 : Start Contactor #1
10 - C2 : Start Contactor #2
11 - GND : Ground
12 - ST : Stop Fuel Solenoid Valve
(ETS - Energized To Stop)
V-AA : Bell / Solenoid Valve / Analog inputs
V: Bell output
W: Test Solenoid Valve
X: Analog inputs
AI1: Discharge Pressure transducer
AI2: Optional additional Discharge Pressure transducer
AI3: Analog Input sensor (depending on the options)
AI4: Analog Input sensor (depending on the options)
AI5: Analog Input sensor (depending on the options)
Y: AC monitoring
Z: CANBUS: UP to ViZiTouch, DOWN to Exp. IO board
AA: Factory reserved power connections
10
Quick Start-Up Guide
The rating label is the most important label. It must be read carefully to ensure the compatibility between the
controller and the installation.
Verify that the controller is installed securely to the wall, or on the mounting stand (optional). Verify the Main
Selector Switch is in the “OFF” position. This selector switch is also called the “HOA” and can be placed in 3
positions: “H” Hand/Manual, “O” OFF, “A” Automatic.
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Open the controller's door and verify that the disconnect switch and all circuit breakers are in the “OFF” position.
Verify and/or install the proper water connections for the water input and the drain. They must be securely installed
and tightened. Refer to the silkscreen markings on the plastic cover.
12
Connect all cables between the engine control panel and the controller engine terminals (Identified as “U” on the IO
board diagram displayed in the Terminal Strips Descriptions in the manual). Secure with the appropriate torque as
indicated on the torque label and verify all connections. Connect the AC main line and ground to the AC terminal in
the controller.
Activate the disconnect switch (if present) and all breakers by setting them to the "on" position. The controller will
boot up for the first time.
13
Once the controller has booted up, the “First Start Up” page appears. Press “User Login” and enter a valid
authorization code. Once logged in, press “Power”.
The “Power” page will automatically validate the power if no alarm is detected and if the power meets the
requirements. Note: The power validation timer might not appear if all is adequate immediately.
To continue to next step, press “ <First Start Up “.
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Press “Engine First Startup” and turn the Main Selector Switch to the “HAND” position.
Note: Before starting the engine, verify that the engine has been officially commissioned (by an authorized engine
representative or service dealer) and that the exhaust pipe is connected properly.
Note: You can choose to skip this step completely by selecting “Skip engine validation step”. This selection will be
recorded in the logs.
- Press on one or both of the green crank buttons to start the engine.
- With the engine started and running, a timer will start counting.
Note: You can choose to bypass the timer by pressing the “Skip” button. This selection will be recordred in the logs.
- During this time, the controller will verify that no alarms are detected. If an alarm appears, stop the engine by
pressing the “STOP” button and then place the Main Selector switch to the OFF position. Take appropriate action to
resolve the alarm that has appeared. Do not stop the engine only by turning the Main Selector switch to the “OFF”
position. If no alarms are detected by the expiration of the timer, stop the engine by pressing the “STOP” button and
then place the Main Selector switch to the OFF position.
To continue to next step, press “ ˂ First Start Up “.
15
Press “Pressure”.
- Verify that the pressure reading on the screen matches with the calibrated pressure gauge installed on the
sensing line.
- Choose the desired units of measurement for pressure reading.
- Adjust, if required, the range of the digital pressure gauge at Max. Pres.
- Insert the Cut-Out and Cut-In pressure values of the fire pump.
- Insert, if so desired, the Cut-Out and Cut-In pressure values of the jockey pump.
Note: The jockey pump Cut-Out and Cut-In values must be set at the jockey pump controller itself. Inserting these
values at the Fire Pump Controller is only for pressure recording data purposes.
To continue to next step, press “ ˂ First Start Up “.
Go back to the controller start-up page and press the “Other Configuration” button. Enter the time and date. Select
the “Automatic shutdown” and the duration the pump will keep running after the automatic stop if an automatic stop
is desired. Select the frequency at which the periodic test will occur, the day of the week, the hour and the duration
of the test. Also, enter the duration of the Manual Run Test.
16
From the “Home” page, verify that the displayed values are correct.
Turn the “Main Selector Switch” to the “AUTO” position to activate the “Automatic” mode. This is the preferred
position and from now on, the “Main Selector Switch” should always remain in that position.
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The “First Start up” is now completed. The controller is fully installed and configured.
18
Main Features
The ViZiTouch
A: Power LED 3 colors: Pulsing green if the ViZiTouch is properly powered.
B: Crank 1 button: Used to manually crank the starter from battery 1 while in "HAND" mode.
C: Crank 2 button: Used to manually crank the starter from battery 2 while in "HAND" mode.
D: Stop button: Used to stop the engine if all starting conditions are gone.
E: Run Test button: Used to start the manual run test. Be aware that water will flow through the drain during the
test.
F: Front USB Connector: USB Device connector used for file download, software updates, service reports.
G: Touch Screen: 7 inch color touch screen LCD with protective cover.
H: Locking mechanism for the protective cover of the screen. Push to open.
I: CANBUS connector for communication with IO board.
J: Side USB connector.
K: Ethernet connector.
Warning
After 2 years of service, the Vizitouch battery may become less efficient and could lose the time after a shutdown.
Alarm Bell
The alarm bell is activated under default faulty conditions stated by the NFPA20 standard.
Any of these conditions will energize the alarm bell but may be silenced, except in some cases, by pressing on the
the “Silence bell” button on the Alarms page. When silenced, the alarm bell restarts ringing if a new fault occurs or if
the alarm conditions remain unchanged after 24 hours. The alarm bell automatically stops ringing if alarm
conditions are not present anymore.
Note: Other optional or user defined conditions can also activate the bell and can be configured by the user. See
section 5 and verify drawings affixed inside the cabinet for more details.
First Setup
The First Setup must be done prior to using the controller. Completing the First Setup is the only way to access the
homepage and enable the automatic mode of the controller.
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ViZiTouch: Manual Rebooting Method
If required, here is the procedure to manually reboot the ViZiTouch:
1- Turn OFF all disconnecting means to de-energize the ViZiTouch. The ViZiTouch's screen should turn black.
2- Press the stop button or wait until the ViZiTouch's LED extinguishes.
3- Wait 10 seconds.
4- Turn ON all disconnecting means.
Pressure Transducer Test
The controller will test the pressure transducer at least once a week if no manual run test or no weekly test has
been conducted. During the test, the pressure reading will drop to zero but the controller will not see it as a starting
request. This pressure drop will be recorded in the “Pump Curve” page and in the logs with the message.
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Home
Home (Menu)
Home
1
2
3
4
5
6
7
The home page displays all controller statuses and important values of the controller. This includes all voltages,
currents, pressure, engine state and status, as well as all timers and cranking sequences.
A- Navigation bar: Pressing this icon will open a navigation menu on the left side of the screen:
1- Go to Home page
2- Go to Alarms page
3- Go to Configuration page
4- Go to History page
5- Go to Service page
6- Go to Download Manuals page
7- Select Controller Language
B- Name of the page.
C- Displays the date, time and ambiant temperature. Press on the temperature display to chose the temperature
unit.
D- Battery chargers 1 and 2: The state of each charger is displayed by changing the color of the charger icon:
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#
1
2
3
4
Color of the box
Green
Green
Red
Grey
Lightning color
Green
Yellow
Red
Grey
Status
Normal activities (bellow 2 amps)
Charging (above 2 amps)
Failure
No AC voltage
E: Alternative current status: Red when there is a failure and green otherwise.
F: Ammeter: Displays the actual current between the charger and the battery in amps.
G: The battery: The battery will be red if it is in failure and green otherwise. The data shows the actual voltage of
the battery and the charger in volts.
H: Starter contactor: Grey when non active (open) and green when they are activated (closed) during a crank.
I: Starter state window: This window only appears during a cranking cycle. The counter inside indicates the step
timer, ranging from 15 to 0 seconds. As there are two cranking modes, "waiting for crank" and "cranking", two
symbols will alternate: a gear during cranking mode and an hourglass during the waiting mode.
J: The starter gear: Grey when non active and green when activated during cranking.
K: The diesel engine: It will be grey if the engine is stopped, green if an "Engine Run" signal is detected and red if a
"Fail to start" occurred, after 6 unsuccessful cranking attempts. Inside the engine two major alarms are represented;
the "low oil pressure" alarm and the "engine high temperature" alarm. These alarms will stop the engine only if it is
running in test mode. When active, the appropriate alarm symbol will turn red.
L: Fuel solenoid valve: This valve controls the flow of fuel to the engine. When the fuel solenoid is activated, the
valve will be horizontal, green and the yellow representation of the fuel will flow through the entire pipe. When the
"Stop Solenoid valve" is activated, the valve will rotate vertically, become red and the yellow representation of the
fuel will stop at the valve, indicating that the fuel does not flow through anymore.
M: Motor starting or stopping cause: A message box will indicate the reason why the motor is running. Possible
choices include, but are not limited to:
Local: (Optional) This start cause is triggered if the engine is locally started directly from its own control panel and
the option is Enabled.
Manual: The controller receives a manual crank request from one or both of the manual crank membrane buttons
while the selector switch is the “HAND” position.
Remote manual: Manual engine starting is activated by a remote start contact.
Deluge: Automatic engine starting is activated by a deluge valve.
Auto: Automatic engine starting is activated by pressure drop.
Remote auto: Automatic motor starting is activated by remote equipment.
Flow: Automatic motor starting is activated by a signal in the FLOW/ZONE START/STOP input.
High zone: Automatic motor starting is activated by a signal in the FLOW/ZONE START/STOP input.
Weekly test: Automatic motor starting is activated by a scheduled test.
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Run test: Automatic motor starting is activated by the run test pushbutton.
Alternating current failure: (Optional) Alternating current failure will count the time following an AC Failure and at the
end of a predetermined time, will start the engine with an AC FAIL request.
A red rectangular box will indicate the reason why the engine is not running despite the fact that a request is being
made. Possible choices include, but are not limited to:
Overspeed: This start cause happens when the controller receives a request to start, but the engines sends an
overspeed signal, thus preventing its ability to effectively start the engine.
Fail to start: This start cause happens when the controller receives a request to start, but a “Fail To Start” alarm is
active after a cranking sequence failure, thus preventing its ability to effectively start the engine.
Low zone not running: A not running lower zone controller prevents the motor from running. This functionality is
optional.
Locked: An interlock signal is preventing the motor from running.
N: Operations timers: This includes the sequential start timer, the run period shutdown timer, the manual test timer,
the weekly test timer and the alternating current failure timer.
O: The pressure gage: It allows for a precise reading of the actual system pressure. The cut-in and cut-out are
represented by a red and green line on the gage, allowing a quick comparison between the actual pressure and the
set points. At the center of the gauge, a digital indicator shows the actual pressure represented also by the needle
of the gauge. Just under of the digital pressure indicator, the actual pressure unit is shown. The maximum allowable
pressure is also indicated on the gauge and will scale the gauge accordingly.
P: HOA Indicator: Displays the current mode. Hand, Off, Automatic.
Q: Actuation Mode: Displays if the controller is Pressure Actuated or Non-Pressure Actuated.
R: Controller type: Displays if the controller is an Automatic or Non-Automatic type.
S: Shutdown mode: Displays if the shutdown on this controller is Automatic or Manual.
P-Q-R-S: If an alarm or a warning is active, a colored rectangle will appear at the bottom of the screen and will
display the error message. This notification will be yellow for a warning and red for an alarm. If more than one error
is active, the display will alternate between the error messages. The messages will disappear when the alarm or
warning starting cause is no longer present.
Screen Saver
After 5 minutes of inactivity on the ViZiTouch, the screen will dim it's brightness to 25%. After 10 minutes of
inactivity on the ViziTouch, the “Black Screen” screen saver will activate. Its goal is to expand the lifetime of the
LCD screen. The screen saver will be instantly deactivated if the engine is running or if an alarm is activated. To
manually deactivate it, simply touch the screen or any membrane button. After deactivation, the screen saver will
always redirect to the “Home” page. It will also log off any user by resetting the security level to 0 and save any new
modifications to the settings.
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Alarms
Alarms (Menu)
This page displays the list of currently active and occurred alarms. Alarms with adjustable parameters can be set in
the Config ˃ Advanced ˃ Alarms pages (see section 6).
An alarm is called ACTIVE when its triggering condition is still valid.
An alarm is called OCCURRED when its triggering condition has been active, but is no longer true.
Alarms representing serious concerns will have a red triangle with an exclamation point in the center at the end of
the alarm message.
Alarms representing simple warnings will have a yellow triangle with an exclamation point in the center at the end of
the alarm message.
Pressing on the Bell Test button will ring the bell for three seconds.
To silence the bell, press the ALARM button or it will silence itself after the expiration of a factory set time.
Pressing on the RESET button will reset OCCURRED alarms only.
The table displays system events:
- Date and time stamp of the alarm in the YYYY.MM.DD format.
- Alarm message.
- State: OCCURRED or ACTIVE.
- Color Code Icon:
Red: The event is an alarm.
Yellow: The event is a warning.
Complete list of alarms:
Common Alarms. A common alarm is an alarm that is activated when one or more of a certain type of conditions
are active. There are 3 common alarm:
Engine Trouble. Activated when one or more of these conditions are active :
- High Coolant Temperature (5)
- Engine Low Coolant Temperature (312)
- Engine Low Oil Pressure (4)
- Engine Fail to Start
- Engine Fail when Running
- Engine Overspeed* (3)
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- ECM Selector Switch in Alternate Position (301)
- ECM Fault (304)
- Engine Fuel Injection Malfunction (302)
- PLD Low Suction Pressure (305)
- High Raw Water Temperature (310)
- Low Raw Water Flow (311)
- Battery Failure 1-2
- DC Failure
- Over Pressure
Pump Room Trouble. Activated when one or more of these conditions are active :
- Fuel Tank Leak
- Low Fuel Level
- High Fuel Level
- AC Failure
- Low Pump Room Temperature
- Low Suction Pressure
- Water Reservoir Low
- Water Reservoir Empty
CTRL Trouble: Important: this relay is normally energized when the controller is in normal condition. The relay is
de-energized when controller trouble is detected (fail safe). Activated when one or more of these conditions are
active :
- Charger Failure 1-2
- DC failure
- Default Solenoid Valve
- Weekly Test Cut-In Not Reached
Regular alarms list:
- AC Failure: Monitors the AC power and activates on a failure.
- DC Failure: Monitor the DC power from the batteries and activates if both batteries fail.
- Battery 1-2 Fail: Monitors the status of batteries and activates on a failure. This occurs when the battery is
disconnected, is of the wrong type or is unable to be recharged.
- Charger 1-2 Fail: Monitors the state of battery chargers and activates on a failure. This occurs when the battery
charger has a defect, is not properly powered, or is unable to provide the needed current. The charger will also
change to Boost Fault mode if during a boost test, the voltage does not rise. A NC dry contact is also connected
from the charger to the IO Board. The alarm will activated if this contact open for the time set on the Charger Fail
alarm page. Charger readings are not updated during cranking and/or running, due to reading instability under load.
As soon as the engine returns to an idle state, all readings and failure analysis are reactivated.
- Service Required: Activates when service is due for the controller. This occurs when the date set in the service
page has passed, or if no service has ever been done.
- Weak Battery 1-2: Activates if the battery voltage falls below the weak battery factory set point.
- Loss of Continuity 1-2: Activates if the engine start contactors are disconnected from the controller.
- Weekly Test Cut-In Not Reached: Activates if the Cut-In is not reached during a manual or a weekly run test. At
the end of the 20s timer, if the Cut-In is not reached, the test may still be successful at starting the engine if the
pressure has dropped by at least 5 PSI.
- Check Weekly Test Solenoid: Activates if the pressure does not drop a minimum of 5 PSI during the manual run
test or the weekly test. Indicates a failure with the Test Solenoid Valve.
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- Pressure Transducer fault detected: Occurs if the pressure reading is out of its normal range. Additionnally, if an
optional dual pressure sensor is installed, it will be activated if the two pressure transducers show different
readings. Further investigation is advised to determine what caused the different readings. Note that the controller
will always choose the lowest pressure reading to determine the actual system pressure.
- Overpressure: Activates if the analog readout of the discharge pressure goes higher than the overpressure set
point in the alarm page.
- Underpressure: Activates if the analog readout of the discharge pressure goes lower than the “Under Pressure”
set point in the alarm page.
- Low Suction Pressure: Activates if the analog readout of the suction pressure is Enabled and goes lower than the
low suction pressure set point in the alarm page.
- Water Reservoir Low: Activates if the “Water Reservoir Low” contact input (IN5) is triggered or if the analog
readout of the water reservoir is Enabled and is lower than the water reservoir low set point in the alarm page.
- Fuel Tank Leak: Activates if the “Fuel Tank Leak” contact input (IN4) is triggered.
- Low Fuel Level: Activates if the “Low Fuel Level” contact input (IN1) is triggered or if the analog readout of the fuel
level is Enabled and goes lower than the low fuel level set point alarm.
- High Fuel Level: Activates if the “High Fuel Level” contact input (IN5) is triggered or if the analog readout of the
fuel level is Enabled and goes higher than the high fuel level set point alarm.
- Engine Fail When Running: Activates if the “Engine Run” signal is lost while the engine is running. The engine will
try to start the cranking sequence once again if the starting causes are not back to normal.
- Engine Fail to Start: Activates if the engine fail to start after the complete 6 attempts crank sequence. The engine
will turn red.
- ECM Selector Switch in Alternate Position: Activates if the specific “ECM” (Electronic Control Module) input (301)
is triggered on the engine connector strip.
- ECM Warning: Activates if the specific “ECM” input (303) is triggered on the engine connector strip.
- ECM Fault: Activates if the specific “ECM” input (304) is triggered on the engine connector strip.
- FIM: Activates if the specific FIM (Fuel Injection Malfunction) input (302) is triggered on the engine connector strip.
- PLD Low Suction Pressure: Activates if the specific PLD (Pressure Limiting Device) input (305) is triggered on the
engine connector strip.
- High Raw Water Level: Activates if the specific input is (310) triggered on the engine connector strip.
- Low Raw Water Flow: Activates if the specific input (311) is triggered on the engine connector strip.
- Engine High Temperature: Activates if the specific “High Temp” input (5) is triggered on the engine connector strip
and the engine is running. A 3 hour timer will start when the engine stops, and if the condition is still present, the
alarm will be activated. This alarm will stop the engine only if triggered during a manual run test or a weekly test.
- Engine Low Temperature: Activates if the specific “Low Temp” input (312) is triggered on the engine connector
strip.
- Engine Low Oil Pressure: Activates if the specific “Low Oil Pressure” input (4) is triggered on the engine connector
strip and the engine is running. This alarm will stop the engine only if triggered during a manual run test or a weekly
test.
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- Engine Overspeed*: Activates if the specific “Overspeed” input (3) is triggered on the engine connector strip and
the engine is running. This alarm will immediately stop the engine and cannot be reset by using the reset button on
the alarm page. The alarm must be reset on the engine itself and the controller must be turned OFF and ON with
the HOA selector switch to complete the reset procedure for this alarm.
- Battery1-2 Overvoltage: Activates if the voltage of the specific battery is higher than the specified overvoltage set
point.
- Water Reservoir High: Activates if the optional “Water Reservoir High” contact input is triggered or if the analog
readout of the water level is Enabled and goes higher than the “High Water Level” set point alarm page.
- IO Exp Comm Error: Activates if communication with the Expansion IO board could not be established for 15
seconds.
- Pump on demand: Activates when the pressure is below the cut-in set-point on an automatic pressure actuated
controller.
- Bell Silenced: Activates when a audible alarm has been silenced.
- Engine Run: Activates when the input “Engine Run“ (2) is active on the engine strip of the IO card.
- Invalid Cut-In: Activates when the Cut-In value is not acceptable. (0 or higher than the Cut-Out).
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Configuration
Config (Menu)
Config
The main configuration page is used to setup all basic configuration parameters and provides a quick means of
changing the most common settings.
There are seven (7) access parameter boxes; Pressure, Periodic Test, Run Test, Automatic Shutdown, Date &
Time, Advanced and User Login. Each parameter requires a specific access level to set or change values.
User Login:
The padlock icon indicates the current authorization level. A locked padlock indicates that only basic settings can be
changed. Press on the padlock to enter an authorization code to unlock additional settings. An unlocked padlock
showing an authorization number indicates that some settings are unlocked. Press on the padlock again when you
have concluded your operation to logout and to save any changes made in the configuration.
Pressure:
The main pressure parameters can be set inside the box at the top of the page.
- Pressure reading: Can be selected as PSI, kPa, bar, FoH, or mH20.
- Input Device: Can be selected as Pressure transducer 1 or 2
- Maximum Pressure: Can be set between the Cut-Out value and 9999.
- Cut-Out: Can be set between the Cut-In value and the Maximum Pressure value. (The Cut-Out should be set
before the Cut-In).
- Cut-In: Can be set below the Cut-Out value.
Periodic Test:
The Periodic Test can be selected as “weekly”, “every other week” or “monthly”. The day of the week, the time of
day for the test and the test Duration can also be specified in this box.
Run Test Configuration:
The Run Test Configuration box is where the duration of the run test time is set. A timer between 1 and 30 minutes
can be selected.
Automatic Shutdown:
If enabled, the Automatic Shutdown will automaticly stop the pump after the demand dissapears. A timer between 1
and 1440 minutes can be selected.
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Advanced:
Go to the advanced configuration pages.
Date & Time Configuration:
Select to display the Date Time page.
NumPad Page
The NumPad is activated every time the user presses on a white square box representing a number that can be
set. On top of the NumPad, the current parameter is shown. The box at the top of the NumPad displays the range
of values accepted for that particular parameter. The box will turn red if the value entered is out of range. Pressing
the “X” button in the circle will set the value to zero “0”. Once a value that falls within the range is selected, the box
will turn blue. The button with a blue “X” inside a white arrow is used as a “backspace”. Pressing the “OK” button
will enter the new value and the screen will return to the previous page. Pressing anywhere outside the numpad
view will cancel the edition process and leave the value previously selected.
Date and Time Page
Select the Year by pressing inside the year box and enter the value, or use the left and right arrows to simply
decrement or increment the value. Likewise, select the month by pressing on the month box and select the value
from the list shown, or use the left and right arrows to cycle through the choices.
Once set, press on the proper day to select the actual day, if different. The time is set by pressing the two square
boxes under the clock; the left sets the hours and the right sets the minutes. Press the Update button to commit the
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changes. A dialog box will appear to confirm the change “Date and Time”. The user may cancel the changes by
pressing the “Cancel” button. Please note that changing the date and time will have an effect on the logs
chronology.
The time zone can also be changed using the box in the bottom-right corner.
User Login Page / KeyPad Page
User Login KeyPad:
This page allows the user to log into a higher security level by entering a password. If the password is valid, the text
field will turn green and if it is invalid, the text field will turn red. An “X” button appears in the text field as soon as a
character is entered, allowing for a quick erase of the written password.
Shortly after being entered, each character will be displayed as an “*”. To view the whole password, press the eye
on the top left corner.
If the password is invalid for a consecutive number of times, the user will be redirected to the “Service Dealer” page,
allowing the user to communicate with the appropriate Service Dealer.
If the password is valid, the “Configuration” page will reload and the access security level will be shown inside the
lock. To log off, click on the lock and the user security level will return to “0”
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Other KeyPads:
The KeyPad is activated every time the user presses on a grey rectangle box with white text representing a text that
can be set. The “X” button allows the user to cancel editing the value. The back arrow erases the last entered
character. Simply click the “OK” button once the value is set. This type of text field is mostly used to generate a
digital text indication for a custom alarm input.
Advanced Configuration Page
Config > Advanced
This page is the portal to all the advanced configuration parameters of the ViZiTouch. Pressing on a tab will redirect
to the corresponding page.
Control Timers
Config > Advanced > Control Timers
This page is used to adjust the timers.
Sequential Start Timer
This timer sets the time delay between a demand becoming active and the starting of the engine. (Optional).
Time Range: 0-3600 Seconds
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Run Period Timer
This timer sets the time the engine will keep running after the demand is resolved.
Time Range: 1-1440 Minutes
Alarms
Configuration > Advanced > Alarms
Most alarms are not configurable in the field, but some are with the appropriate password level. If it's configurable,
the checkboxes will be in white. Otherwise the checkboxes will be grey. Also, the two last fields: Value Usage and
Analog Value are not always visible.
Start Test: The alarm can be tested using this button. This test will only announce the chosen alarm. It will activate
the bell if the alarm is audible and will activate any output relays associated with this alarm. The test will not activate
other common alarms or other components. To stop the testing, press the “Stop Test” button.
Enable: Check this box to enable the Alarm/Warning.
Alarm: Makes this signal an alarm (red display). Otherwise, it will be a warning (yellow display).
Audible: Check this box to make the bell ring while this alarm is active.
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Silence Duration: Set the time this Alarm will remain silenced.
Annunciate when occurred: Check this box to keep activated any associated relay even when this alarm has
occurred.
Acknowledgeable: Check this box to make the alarm acknowledgeable. If an alarm is ackowledged, the bell will be
silenced and the alarm IO board Output will stop being active. To acknowledge an alarm, go to the alarm list page
and press the blue “Active” status on the right of the alarm. The “Active” status should change to “Acknowledge”.
Timer On: It is the time delay between the triggering of the condition and the activation of the alarm.
Timer Off: It is the time delay between the stopping of the condition and the deactivation of the alarm.
Analog Value Usage: It is used to describe the activation range of the alarm. “Lower Than”, “Higher Than” and
“Between” can be selected. The corresponding value has to be entered.
Text: This field can be used to change the name of the alarm that will be displayed while this alarm is active. Note
that changing the factory set name of an alarm will disable any translation of this alarm to different languages.
Hysteresis: In the “Analogue Value Usage” field, it is possible to chose “Hysteresis Low Setpoint” and “Hysteresis
High Setpoint”. Both Analog Low Value and High Value needs to be selected for this mode to be effective. For the
“Hysteresis Low Setpoint”, the alarm will be trigger if the chosen signal goes below the “Low Setpoint” and will be
reset when the signal rise above the “High Setpoint”. For the “Hysteresis High Setpoint”, the alarm will be trigger if
the chosen signal goes above the “High Setpoint” and will be reset when the signal falls below the “Low Setpoint”.
Chargers and Batteries
Config > Advanced > Chargers and Batteries
This page is used to adjust some features of the batteries and chargers.
Charger 1-2 reference voltage: This is the normal voltage of the chargers in float mode and serves as a reference to
trigger the “charger fail” alarm.
Weak battery 1-2: Under this voltage, the batteries are considered weak. The alarm “weak battery” is then
activated.
Battery 1-2 overvoltage: Over this voltage, the batteries are considered in overvoltage. The alarm “battery
overvoltage” is then activated.
Battery missing count before alarm: This is the number of “battery missing” test that needs to be failed before the
“battery failed” alarm is triggered.
33
Charger boost health monitor enable: If checked, this feature will enable the monitoring of the chargers boost
health.
Charger boost health test interval: This is the minimum interval between two charger boost tests.
Charger boost detection threshold: This is the minimum value the voltage has to raise during a boost test for the
test to be consider as a success.
Starter Configuration
Config > Advanced > Starter Configuration
This page displays information on the charger configuration. If more than one starter is installed, it will be possible
to choose which starter will be activated first.
Cranking Time: Duration of a cranking step.
Rest between cranking: Durantion of the pauses between two cranking steps.
Cranking Steps: Number of times the controller will activate the starter.
Sensor Selection
Config > Advanced > Sensors
Important Notice!
Every analog sensor cable used for this controller should be shielded. The shield has to be grounded on the motor
side. Not complying to these recommendations may affect the controller good functioning and void its warranty.
34
Five analog sensors, an AC voltage sensor, two battery current sensors and two battery voltage sensors can be
calibrated by accessing this page. The Analog Input 1 is dedicated to the Pressure Transducer. The other Analog
Input depends on the controller options.
Every sensor, except the AC Voltage can be calibrated the same way. The Signal destination, the Unit type, the
Unit, the Min and Max values are variables that are set in factory but the calibration can be made in the field.
There are three ways of calibrating a sensor that can be chosen in the windows below "Sensor value".
-Sensor value: Connect an external measurement tool that is already calibrated (like a Manometer to calibrate a
pressure sensor). Bring the system to calibrate to a low point. While looking at the measurement tool, press the
read button (the button with a circular arrow). The value that was displayed on the measurement tool when the read
button was pressed needs to be enter in the "Low" window below the Desired value. Repeat these steps with a high
value. Then press compute. For the PT1, only a high value is required.
-Theorical voltage: Use a graphic of the theorical sensor's voltage response (usually given in the datasheet of the
sensor). Enter a low point (value, voltage) and a high point. Then press compute.
-Theorical current: Same as the theorical voltage, but with amperes.
For better results, use two points that are far apart, but in the normal range of the sensor.
For the AC voltage, only one point is needed.
35
For the pressure transducer PT1, the low point (zero) is automatically acquired during first power up. It can be reacquired by pressing the blue round arrow. The high point needs to be entered in order to calibrate the sensor.
Outputs
Config > Advanced > Outputs
This page is used to choose the logic of the signals that will activate the Outputs on the IO board and to test those
Outputs.
- CTRL Trouble (TB1)
- Engine Run (TB2)
- HOA in Manual or OFF (TB3)
- Engine Trouble (TB4)
- Pump Room Trouble (TB5)
- Optionnal Output 1 (TB6)
- Fuel Solenoid (1)
- Stop Solenoid (12)
- Contactor 1 (9)
- Contactor 2 (10)
- Test Solenoid Valve
- Alarm Bell
Pressing on an Output will lead to this page:
36
The first box from the top is used to change the name of the Output. For the output's logic, a combination of 5 digital
inputs can be selected. Each input can be an alarm or a signal from a list and can be inverted by pressing the
NO/NC contact symbol at the left of the screen. A logical AND or OR can combine the chosen inputs and the exit
can also be inverted by pressing the NO/NC contact symbol at the right of the screen.
Pressing the “Test” button, at the bottom of the screen, will change the state of the output for one second. Note:
activating some outputs may cause the motor to start.
Update Program Page
Config > Advanced > Update Program
This page is used to update the controller software. A USB key or a network connection with the software update is
needed.
37
Factory Settings
Config > Advanced > Factory Settings
This page is used to visualize the program version, the serial number and the model of the controller.
Some parameters can be changed on this page, but be careful, modifying a parameter will change the basic
operation of the controller. Afterwards the controller may no longer respect the NFPA standard.
- Automatic Controller: Enable automatic starting causes.
- Pressure Actuated Controller: Enable the automatic controller to start following a pressure drop.
It is possible to reload a past configuration by pressing the "reload configuration" button. Dates with an "*" are
settings following a "Service".
Do not change a parameter on this page without previously consulting a Tornatech representant.
Interlock Lockout
Config > Advanced > Interlock Lockout
This page is used to configure the Lockout input and the Interlock output parameters. To be active those options
need to be assigned to an Input or an Output on the IO board.
Lockout is an Input that disables the engine from starting.
-Shutdown Engine: If enabled, the lockout signal will also act as a shutdown and will stop the engine if it is running.
-Enable in Manual: If checked, activation of the lockout input will prevent the Manual start.
-Enable in Automatic: If checked, activation of the lockout input will prevent the Automatic start.
38
-Enable in Remote: If checked, activation of the lockout input will prevent the Remote start.
-Enable in Flow: If checked, activation of the lockout input will prevent the Flow start.
Interlock is an Output that prevents a second engine from starting.
-Engine Run Required: If enabled, the controller will wait to have Engine Run before putting Interlock active.
-Enable in Manual: If checked, this option will activate the output Interlock on a Manual start.
-Enable in Automatic: If checked, this option will activate the output Interlock on a Automatic start.
-Enable in Remote: If checked, this option will activate the output Interlock on a Remote start.
-Enable in Flow: If checked, this option will activate the output Interlock on a Flow start.
Inputs
Config > Advanced > Inputs
This page is for vizualisation purpose only. It allow the user to verify which signal is mapped on which controller's
input.
I/O Card Info
Config > Advanced > IO Card Info
This page is used to visualize the ViZitouch and the IO Card registers by pressing on the blue arrows on the right of
the screen. Expansion Cards can also be installed via this page.
39
Network
Config > Advanced > Network
This page displays the IP address, the Subnet Mask, the Default Gateway and the DNS1-2-3 of the controller. All
those parameter can be changed manually by checking the box on the upper left corner. To apply the change,
press on the blue arrow in the bottom right corner.
Reboot ViZiTouch
Config > Advanced > Reboot ViZitouch
If this button is pressed, the ViZiTouch will reboot. Any change will be saved.
40
History
History (Menu)
History
This page is used to access all data related to events, statistics, pressure history, power logs and the downloading
of this information via one of the two USB ports.
-Events: This button leads to the “Events” page, which displays the events from the most recent 500 logs. Each
event log contains the date and time of occurrence as well as a brief description of the event.
-Pressure/Power Curves: This button leads to the “Pressure Curves” / “Power Curves” page accordingly, which
displays all relevant pressure/power information from the most recent 500 logs.
-Saved Logs: This button leads to a page where past logs can be viewed.
-Pump Curve: This button leads to the “Pump Curves” page.
-Statistics: This button leads to the “Statistics” page, which leads to “All Time Statistics”, “First Service Statistics”
and “Last Service Statistics” pages.
-Download: This button leads to the “Download” page, which allows the user to download information, including the
user manual, drawings, logs, statistics and configuration.
41
Events Page
History > Events
The Events Page shows the events from the last 500 logs which occurred in chronological order. The first column is
the date, the second one is the time of occurrence and the third column is the “Event message”. To obtain a log that
is older than thoses events, visit the “Saved Logs”.
Pressure Curves
History > Pressure Curves
On this page, a graphic of the “System Pressure”, the “Cut-in”, the “Cut-Out”, the main pump “Engine Run” and the
“Jockey Pump Run” through time can be viewed. By pressing on the screen, the caption will disappear or will be
displayed. The time scale can be changed by pressing the time span desired on top of the screen (from 1 minute to
2 weeks). The blue arrows on both sides of the graphic are used to navigate through time. The blue button in the
bottom left corner leads to the table used to generate this graph.
42
This table allows viewing of the exact values used to generate the Pressure Curves with the precise time. Pressing
the blue button on the top left corner will return to the graph page.
Power Curves
History > Power Curves
On this page, a graphic of the “Battery 1 Voltage”, the “Battery 2 Voltage”, the “Battery 1 Current” and the “Battery 2
Current” through time can be viewed. By pressing on the screen, the caption will disappear or will be displayed. The
time scale can be changed by pressing the time span desired on top of the screen (from 1 minute to 2 weeks). The
blue arrows on both sides of the graphic are used to navigate through time. The blue button in the bottom left corner
leads to the table used to generate this graph.
43
This table allows viewing of the exact values used to generate the Power Curves with the precise time. Press the
blue button on the top left corner to return to the graph page.
Saved Logs
History > Saved Logs
This page is used to access all past log files. Each log file is a CSV file containing the time, the date, the Cut-in, the
Cut-out, the system pressure, the battery voltages and currents, the engine run signal, the jockey pump run signal
and the log event message. Each file can contain up to 1 MB of data. The month and year is integrated in the title.
At the beginning of each month, a new CSV file is created. Each time a CSV file is full, a new one is created with an
incremented number in the title. Press on the file to consult this content.
44
The logs are arranged chronologically. To select the displayed data, press on the filter icon in the top center of the
screen.
From this page, the selected values will be displayed. Press on “Log File” at the top left of the screen to go back to
the logs table.
Pump Curves
History > Pump Curves
This page is intended to help the customer generate the pump performance curve. In Auto mode, the controller will
sample the water flow exiting the pump, the system pressure and the suction at the entrance of the pump. The
appropriate sensor has to be installed for this mode to work. Each time the variation of a variable is important
enough, the controller will record the values and ring the bell. In manual mode, the user can manually enter the
values to generate the pump curve.
45
Statistic
History > Statistics
This page leads to 3 other Statistics pages: “All Time Statistics”, “First Service Statistics” and “Last Service
Statistics”.
All Time Statistics
History > Statistics > All Time Statistics
The “All Time Statistics” contains two parameters:
- Since: The date the controller has been powered for the first time.
- On Time: The amount of time the controller has been On for.
46
First Service Statistics
History > Statistics > First Service Statistics
This page allows the user to view the “First Setup Statistics”. The parameters are:
From:
- Since: Date of the first setup
- On Time: Time the controller spent On, in DAYS-HOURS:MINUTES-SECONDS
Engine:
- On Time: Time the engine spent On, in DAYS-HOURS:MINUTES-SECONDS
- Start Count: Number of times the engine has started
- Last Started on: Last time the engine started
Pressure:
- Minimum: Smallest pressure value
- Minimum Occurred On: Date the smallest value happened
- Maximum: Biggest pressure value
- Maximum Occurred On: Date the biggest value happened
- Average: Average pressure since first start-up
Temperature
- Minimum: Smallest temperature value
- Minimum Occurred On: Date the smallest value happened
- Maximum: Biggest temperature value
- Maximum Occurred On: Date the biggest value happened
- Average: Average temperature since first start-up
Jockey Pump Running
- On Time: Time the Jockey Pump spent On, in DAYS-HOURS:MINUTES-SECONDS
- Start Count: Number of times the Jockey Pump has started
- Last Started On: Last time the Jockey Pump started
47
Last Service Statistics
History > Statistics > Last Service Statistics
This page allows the user to view the “Last Setup Statistics”. The parameters are the same as the ones from the
“First Setup Statistics” page but from the “Last Service”.
Download
History > Download
This page is used to download Statistics, PCB information, name plate information, logs, the manual, the factory
settings and the current settings. A USB key needs to be inserted in the USB slot prior to entering this page in order
to download.
48
Service
Service
Informations on how to reach technical support, concerning the commissioning date, the last service date and the
next service due date is available on this page. It is the client responsibility to make sure that the proper
maintenance is done on the controller. A reminder for the “Service” can be selected from these options: OFF, ½
year, 1 year, 1 ½ years, 2 years and 3 years. The next service will be determined using the last service and the
chosen service interval. This service must be done by an accredited technician.
A proper password must be enter for the “Service Done” button to be available. This button should only be pressed
by an authorized person after a completed service.
The “Live View” page is where the user can grant or refuse the remote access demands.
The “Nameplate Information” page contains all the information found on the nameplate.
The Jockey Pump Cut-Out and Cut-In can be set on this page.
It is possible to install a custom Service card on this page. Contact Tornatech for more information.
49
Download Manuals
Pressing on the question mark will redirect to the download page. A pdf version of the manual can be downloaded
on an USB device.
50
Language
The language displayed on the ViZiTouch can be selected on this page.
51
Technical Documents
How to Test:
Charger 1 Fail
Unpower the charger 1 by putting the circuit breaker in the off position.
Charger 2 Fail
Unpower the charger 2 by putting the circuit breaker in the off position.
DC Failure
Switch Circuit Breaker 3 (CB3) and Circuit Breaker 4 (CB4) in Off position or disconnect #6 and #8 engine wires (See
drawing for more details).
Faulty Pressure Transducer
Disconnect the Pressure Transducer. Depending on your sensor type, put a jumper between positive pin (left) or
negative pin (right) and signal pin (middle) of this connector (See drawing for more details).
Weekly Test Check Solenoid Valve
Disconnect the Solenoid Valve. Switch the HOA selector switch to the Auto position. Press the Run Test button
(Yellow button on the membrane). Wait until the test ends. (Note: The engine will start.)
Controller Trouble
To activate this common alarm, at least one of the following alarms must be active: Charger Failure 1, Charger
Failure 2, DC Failure, Faulty Pressure Transducer or Weekly Test Check Solenoid Valve.
Low Fuel Level
Put a jumper between Low Fuel Level input and ground (See drawing for more details).
High Fuel Level
Put a jumper between High Fuel Level input and ground (See drawing for more details).
Fuel Tank Leak
Put a jumper between Fuel Tank Leak input and ground (See drawing for more details).
AC Failure
Make sure both batteries are connected and all circuit breakers are in the ON position. Switch the disconnect switch
to "OFF" position.
Low Ambient Temperature
You need to be logged in to modify these settings. Go to Config>Advanced>Alarms>Low Ambiant Temp. Change the
Low Ambiant Temperature setpoint to the maximum allowable.
High Ambient Temperature
You need to be logged in to modify these settings. Go to Config>Advanced>Alarms>High Ambiant Temp. Change
the High Ambiant Temperature setpoint to the minimum allowable.
Low Suction Pressure
Disconnect Suction Pressure connector. Depending of your sensor type, put a jumper between positive pin (left) or
negative pin (right) and signal pin (middle) of this connector (See drawing for more details). Start the engine.
Water Reservoir Empty
Put a jumper between Water Reservoir Empty input and ground (See drawing for more details).
52
High Water Level
Put a jumper between High Water Level input and ground (See drawing for more details).
Water Reservoir Low
Put a jumper between Water Reservoir Low input and ground (See drawing for more details).
Pump Room Alarm
To activate this common alarm, at least one of the following alarms must be active: Low Fuel Level, High Fuel Level,
Fuel Tank Leak, AC Fail, Low Ambient Temperature, High Ambient Temperature, Low Suction Pressure, Water
Reservoir Empty, High Water Level or Water Reservoir Low.
Fail to Start
Disconnect #1, #9, #10 and #12 engine wires (See drawing for more details). Start the cranking sequence (Example:
Remove Remote Automatic Start jumper). Wait until the cranking sequence ends.
Overspeed
If your engine has an overspeed switch, switch it to the ON position. If not, disconnect #3 engine wire (See drawing
for more details) and put a jumper between #3 and #6. (Note: You don't need to start the engine to activate this
alarm.)
Electronic Control Module Selector Switch in Alternate Position (301)
Disconnect #301 engine wire. Put a jumper between #301 input and ground (See drawing for more details).
Fuel Injection Malfunction (302)
Disconnect #302 engine wire. Put a jumper between #302 input and ground (See drawing for more details).
Electronic Control Module Warning ( 303 )
Disconnect #303 engine wire. Put a jumper between #303 input and ground (See drawing for more details).
Electronic Control Module Fault ( 304 )
Disconnect #304 engine wire. Put a jumper between #304 input and ground (See drawing for more details).
Low Engine Temperature (312)
Disconnect #312 engine wire. Put a jumper between #312 input and ground (See drawing for more details).
Low Oil Pressure
Disconnect #4 engine wire (See drawing for more details). Put a jumper between #4 and ground. Start the engine.
High Engine Temperature
Disconnect #5 engine wire (See drawing for more details). Put a jumper between #5 and ground. Start the engine.
Battery 1 Failure
Disconnect #6 engine wire (See drawing for more details).
Battery 2 Failure
Disconnect #8 engine wire (See drawing for more details).
Weak Battery 1
You need to be logged in to modify these settings. Go to Config>Advanced>Alarms>WeakBattery1. Change the
Weak Battery 1 setpoint to the maximum allowable.
Weak Battery 2
You need to be logged in to modify these settings. Go to Config>Advanced>Alarms>WeakBattery2. Change the
Weak Battery2 setpoint to the maximum allowable.
Battery 1 Overvoltage
You need to be logged in to modify these settings. Go to Config>Advanced> Alarms>Battery1Overvoltage. Change
the Overvoltage Battery 1 setpoint to the minimum allowable.
53
Battery 2 Overvoltage
You need to be logged in to modify these settings. Go to Config>Advanced> Alarms>Battery2Overvoltage. Change
the Overvoltage Battery 2 setpoint to the minimum allowable.
Loss of Continuity 1
Disconnect #9 engine wire (See drawing for more details). Wait 1-2 minutes.
Loss of Continuity 2
Disconnect #10 engine wire (See drawing for more details). Wait 1-2 minutes
Underpressure
You need to be logged in to modify these settings. Go to Config>Advanced> Alarms>Underpressure. Change the
Underpressure setpoint to the maximum allowable.
Overpressure
You need to be logged in to modify these settings. Go to Config>Advanced> Alarms>Overpressure. Change the
Overpressure setpoint to the minimum allowable.
Low Pneumatic Pressure
Put a jumper between the Low Pneumatic Pressure input and ground (See drawing for more details). Take note that
this alarm will stop the pneumatic cranking sequence.
Engine Trouble
To activate this common alarm, at least one of the following alarms must be active: Fail to start, Overspeed,
Electronic Control Module Selector Switch in Alternate Position (301), Fuel Injection Malfunction (302), Electronic
Control Module Warning (303), Electronic Control Module Fault (304), Low Engine Temperature (312), Low Oil
Pressure, High Engine Temperature, Battery 1 Failure, Battery 2 Failure, Loss of Continuity 1, Loss of Continuity 2,
Overpressure or Low Pneumatic Pressure
Low Spare Temperature
Disconnect the Spare Temperature connector. Depending of your sensor type, put a jumper between positive pin
(left) or negative pin (right) and signal pin (middle) of this connector (See drawing for more details).
WT CI Not Reached
You need to be logged in to modify these settings. Go to the Config page. Change Cut-In to 0. Press Run Test button
(Yellow button of the membrane). Wait until the test ends.
Flow Start
Put a jumper between the Flow Start input and ground (See drawing for more details).
Cooling No Flow
Put a jumper between the Cooling No Flow input and ground (See drawing for more details).
Flow Meter On
Put a jumper between the Flow Meter On input and ground (See drawing for more details).
Engine Fail When Running
Start the engine. Depending of your engine type, disconnect #1 or put a jumper between #12 and #6 to stop the
engine. (See drawing for more details).
IO Diesel Communication Error
Press Reset button of the Diesel IO Board (Small button close to the phone jack)
IO Expansion 1 Communication Error
Press the Reset button of the Expansion 1 IO Board (Small button close to the phone jack)
IO Expansion 2 Communication Error
Press the Reset button of the Expansion 2 IO Board (Small button close to the phone jack)
54
IO Expansion 3 Communication Error
Press the Reset button of the Expansion 3 IO Board (Small button close to the phone jack)
IO Expansion 4 Communication Error
Press the Reset button of the Expansion 4 IO Board (Small button close to the phone jack)
Low Pump Room Temperature
Put a jumper between Low Pump Room Temperature input and ground (See drawing for more details).
Main Relief Valve Open
Put a jumper between Main Relief Valve Open input and ground (See drawing for more details).
Pump on Demand
Open the pressure line to simulate a pressure drop. The engine will start and the Pump On Demand warning will
appear.
Invalid Cut-In
You need to be logged in to modify these settings. Go to the Config page. Change the Cut-In to 0. (Note: The engine
will start.)
Pneumatic Fail to Start
Disconnect the TB6 relay connector. Disconnect #1, #9, #10 and #12 engine wires (See drawing for more details).
Start cranking sequence (Example: Remove Remote Automatic Start jumper). Wait until the cranking sequence ends.
Hydraulic Fail to Start
Disconnect the TB6 relay connector. Disconnect #1, #9, #10 and #12 engine wires (See drawing for more details).
Start cranking sequence (Example: Remove Remote Automatic Start jumper). Wait until the cranking sequence ends.
Patents
Country
CA
US
CA
CA
US
US
EP
AE
AE
CA
US
AE
EP
CA
US
Title
Mechanical activator for contactor
Mechanical activator for contactor
Mechanical activator for electrical contactor
Mechanical activator for electrical contactor
Mechanical activator for electrical contactor
Mechanical activator for electrical contactor
Mechanical activator for electrical contactor
Mechanical activator for electrical contactor
Mechanical activator for electrical contactor
Fire pump digital operator
Fire pump digital operator interface
Fire pump digital operator interface
Fire pump digital operator interface
System and method for detecting failure in a pressure sensor of a fire pump system
System and method for detecting failure of a pressure sensor in a fire pump system
Grant No
2741881
US8399788B2
165512
165514
D803794
Patent pending
002955393-0001/2
Patent pending
Patent pending
163254
D770313
Patent pending
002937250-0001
Patent pending
Patent pending
55
TORNATECH MODEL GPD DIESEL FIRE PUMP CONTROLLER
PRE- FIELD ACCEPTANCE TEST
CHECK LIST
Note: This document should be an official indication of whether or not the installation and general condition
of the equipment is adequate for a field acceptance test. This document should also aid the individual
responsible for executing the field acceptance test to decide whether or not to carry out the field acceptance
test of the equipment.
Installation Check List:
YES
NO
Verify that the nameplate voltages of the Fire Pump Controller corresponds with the AC
1
voltage available and the DC starting voltage of the engine.
Visual inspection for any damage to the exterior of the Fire Pump Controller. Make sure
2
the enclosure, alarm bell, selector switch, membrane and display are not damaged.
Verify that the Fire Pump Controller has been installed within sight of the pump and engine
3
or motor.
Verify that the Fire Pump Controller has been installed not less than 12 inches from the
4
floor of the mechanical room.
Verify that all electrical connections to the Fire Pump Controller are done using liquid tight
5
conduit and connectors.
With the Fire Pump Controller door open, visually inspect for any drill chips, dirt or foreign
6
objects in the bottom of the enclosure, loose wires, broken components and general
proper electrician workmanship.
Verify that the correct AC voltage is supplied to the controller by taking a voltage reading at
7
the L1 & N (120V) or L1 & L2 (220-240) terminals.
Verify that the terminal connections between the Fire Pump Controller and the engine (1 to
8
12 and 301,302,303,304,305,310,311,312) are properly done.
Verify that wiring to terminals #6, #8 (batteries) and #11 (ground) are of the appropriate
9
gauge size. See label inside controller.
10 Verify proper grounding of the Fire Pump Controller.
Initial Power-Up Check List:
YES
NO
1
Verify that the selector switch is in the “OFF” position
With the Fire Pump Controller door open, turn to “ON” the circuit breakers CB3 and CB4
2
(DC) then CB1 and CB2 (AC), then IS1. This sequence is very important.
Close the Fire Pump Controller door. Verify on the ViZiTouch Homepage that the correct
3
battery voltage appears.
Place the selector switch in the “HAND” position. Verify that no alarms are displayed on
4
the screen.
Place the selector switch in the “AUTO” position. Verify that no alarms are displayed on the
5
screen.
Manual and Automatic Start Check List:
YES
NO
1
Place the selector switch in the “Hand” position.
Verify the starting of the engine by pressing the “Battery # 1 Manual Crank” membrane
2
button.
3
Stop the engine by placing the selector switch to the “OFF” position.
Verify the starting of the engine by pressing the “Battery # 2 Manual Crank” membrane
4
button.
5
Stop the engine by placing the selector switch to the “OFF” position.
Set the Cut-Out and Cut-In settings by following the ViZiTouch documentation. You need
6
to be logged in to modify these settings. Verify the automatic start by dropping the system
pressure below the Cut-In setting.
Stop the engine by pressing the “Stop” pushbutton. Note: The engine will only stop if the
7
system pressure is above the Cut-Out setting.
56
Tornatech Controller S/N: _________________________________________
Installation address: _________________________________________
_________________________________________
_________________________________________
Check list completed?
_____________Yes
_____________ No
Check list completed by:
__________________________________________
Company:
__________________________________________
Date:
__________________________________________
Witnessed By: __________________________________________
Comments:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
57
TORNATECH MODEL GPD
DIESEL ENGINE FIRE PUMP CONTROLLER
FIELD ACCEPTANCE TEST REPORT
Note: This document is the Tornatech official Field Acceptance Test report which follows the latest NFPA 20
requirements of article 14.2.6 Controller Acceptance Test pertinent to diesel engine driven fire pump
controllers. Tornatech strongly recommends that a pre-field acceptance verification (Tornatech document
GPD-PREFAT-001-E Pre-Field Acceptance Test Check List) be completed before this official field acceptance
test.
Complete this first section if it was not completed during the Pre-Field Acceptance test
Manual and Automatic Start Check List:
YES
NO
1
Place the selector switch in the “Hand” position.
Verify the starting of the engine by pressing the “Battery # 1 Manual Crank”
2
membrane button.
3
Stop the engine by placing the selector switch to the “OFF” position.
Verify the starting of the engine by pressing the “Battery # 2 Manual Crank”
4
membrane button.
5
Stop the engine by placing the selector switch to the “OFF” position.
Set the Cut-Out and Cut-In settings by following the ViZiTouch documentation. You
6
need to be logged in to modify these settings. Verify the automatic start by dropping
the system pressure below the Cut-In setting.
Stop the engine by pressing the “Stop” pushbutton. Note: The engine will only stop if
7
the system pressure is above the Cut-Out setting.
Battery # 1
YES
NO
1
3 manual starts
2
3 automatic starts
3
1 RUN TEST start
4
1 remote/deluge valve start
5
Start and Run the engine at full speed after 1 crank cycle
Battery # 2
YES
NO
1
3 manual starts
2
3 automatic starts
3
1 RUN TEST start
4
1 remote/deluge valve start
5
Start and Run the engine at full speed after 1 crank cycle
Visual/Audible Alarm Verification
YES
NO
Battery failure:
- On the terminal strip, disconnect wire #6 for battery1. Wait for the alarm, then
reconnect the wire.
- On the terminal strip, disconnect wire #8 for battery2. Wait for the alarm, then
1
reconnect the wire.
- Audible and visual alarm will appear for battery failure and controller trouble.
Note: it is important to return the wires back to their original place and reset the
alarms in order to continue the tests.
Charger failure:
- Switch either circuit breaker #1 (CB1) or circuit breaker #2 (CB2) to the OFF
position to test either charger.
2
- Audible and visual alarm will appear for charger failure and controller trouble
Warning: Do not switch both CB1 and CB2 off at the same time.
Note: it is important to return the circuit breaker back to its original position and reset
the alarms in order to continue the tests.
Engine high coolant temperature:
- Start the engine either manually or automatically.
- With the engine running, place a jumper between terminals 5 & 11 or simulate high
3
coolant signal coming from the engine.
- If the engine was started manually, a visual and audible alarm will be present and
the engine will not shutdown. To shutdown, turn the selector switch to the OFF
position.
58
- If the engine was started automatically, a visual and audible alarm will be present
and the engine will not shutdown. To shutdown, turn the selector switch to the OFF
position.
- Note: Please remove the jumpers and reset the alarm in order to continue to the
next simulation.
Engine low oil pressure:
- Start the engine either manually or automatically.
- With the engine running, place a jumper between terminals 4 & 11 or simulate
engine low oil pressure from the engine. The alarm will annunciate after 8 seconds.
- If the engine was started manually, a visual and audible alarm will be present and
the engine will not shutdown. To shutdown, turn the selector switch to the OFF
4
position.
- If the engine was started automatically, a visual and audible alarm will be present
and the engine will not shutdown. To shutdown, turn the selector switch to the OFF
position.
Note: Please remove the jumpers and reset the alarm in order to continue to next
simulation.
Engine Overspeed:
- Start the engine either manually or automatically.
- With the engine running, place a jumper between terminals 6 & 3 or simulate
overspeed from the engine.
5
- An audible and visual alarm will be present and the engine will shutdown whether it
was started manually or automatically.
Note: Please remove jumpers and reset the alarm in order to continue to next
simulation.
Note: The speed switch must be reset on the engine itself.
Engine fail to start:
- At the terminal strip, disconnect wires #9 and #10
- Place the controller selector switch to Auto and initiate automatic engine start or
start engine by pressing the Run Test Button
The controller will go through its cranking cycle as follows:
- 15 second cranking from battery #1
6
- 15 second rest
- 15 second cranking from battery #2
- 15 second rest
- This cycle will repeat itself three times per battery, hence six times.
- Audible and visual alarm for engine fail to start will appear.
- Switch the engine control panel back to OFF position and reset the alarm.
Stop the engine by pressing the “Stop” pushbutton. Note: The engine will only stop if
7
the system pressure is above the Cut-Out setting.
Field Settings:
Cut-Out Pressure:
________
Cut-In Pressure:
________
Minimum run period timer activated?
Yes: _____ Set at _____minutes.
No: _____
Sequential Start Timer?
Yes: _____ Set at _____seconds.
No: _____
Weekly Test Enabled?
Yes: _____
Start (date and time) ___________
No: _____
Stop (date and time) ___________
59
Alarm Contacts Connections:
Selector switch in OFF or HAND connected? _____Yes _____ No
Engine Run connected?
_____Yes _____ No
Engine Trouble connected?
_____Yes _____ No
Controller Trouble connected?
_____Yes _____ No
Other contacts supplied and connected?
Yes: _______________________________________________________
No: _____
Tornatech Controller S/N: _________________________________________
Installation address:
_________________________________________
_________________________________________
Field Acceptance Test completed? _____Yes _____ No
Field Acceptance completed by:
__________________________________________
Company:
__________________________________________
Date:
__________________________________________
Witnessed By:
__________________________________________
Company:
__________________________________________
The undersigned witness has been made aware of the NFPA20 article 14.4 Periodic Inspection, Testing and
Maintenance which stipulates that “Fire pumps shall be inspected tested and maintained in accordance with NFPA25
– Standard for the Inspection, Testing and Maintenance of Water Based Fire Protection Systems”
Comments: _____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
60
61
0
A
1
2
3
4
6
7
PER QUOTE DRAWING No.
Diesel Engine Fire Pump Controller
24VDC Negative Ground
Low Fuel Level Switch
5
0
DD/MM/YY
DESCRIPTION
REV.
Model:GPD
8
NYC
Dpt of Building
Approved
As Built
DRAWING
07/07/20 NUMBER
Built to the latest edition of the NFPA 20 standard
A
A 1124683-S1
B
B
0.5" MNPT
Electrical Connections Under
Removable Cover
3.5" Nominal
C
C
Float Switch Configuration
1-1/4" NPT
D
D
The contact is CLOSED when float is above the
liquid level.
The contact is OPEN when the float is in the liquid
E
E
F
F
(2-¾" - 27-½")
Adjustable
Contact Rating:
Maximum 250V, 20W
(Switch REED)
Pilot Duty Switch
How to invert a normally open contact to a
normally closed contact
G
G
Instructions:
H
H
- Fitting Size: 1-1/4" NPT
- Length of Assembly: 2-3/4" - 27-1/2"
0.5"
- Diameter of Switch: 1-1/4"
I
0
1
2
3
By Juan Manuel Flores Palacios
at 7:11pm, Jul 22, 2020
4
5
I
6
7
Copyright © 2020 Tornatech Inc. All right reserved. This drawing and the information contained or depicted herein are the sole property of Tornatech Inc. Copies are communicated to the recipient in strict confidence and may not be retransmitted, published, reproduced, copied or used in any manner, including as the basis for the manufacture or sale of any products, without the express prior written consent of Tornatech Inc.
8
P.1
0
3
6
7
8
NYC
Dpt of Building
Approved
DD/MM/YY
DESCRIPTION
REV.
Model:GPD
0
As Built
DRAWING
07/07/20 NUMBER
Built to the latest edition of the NFPA 20 standard
54
14
53
BATT.
+ _
E
J44
(P.2 / D3)
CB1
63 11
B1 B2
15 16
ALARM
SUPPLY
L
Com NO NC
17 18
BATT.
+ _
N
13 54
83 11
BOOST
ALARM
B1 B2
Com NO NC
19 20
21 22
SUPPLY
L
N
14 54
C
J107 / CF2-G
(P.2 / D6)
J107 / B2+_B2(P.2 / D6)
To I/O Diesel Board
D
To I/O Diesel Board
13
To I/O Diesel Board
To Vac
G
BOOST
J105 / G-83
(P.2 / C8)
L'
B
BC2
Charger 2
To I/O Diesel Board
L
BC1
Charger 1
CB2
J106 / CF1-G
(P.2 / D5)
N'
F1
1L
A
A 1124683-S1
To I/O Diesel Board
N
J106 / B1+_B1(P.2 / D5)
1N
To I/O Diesel Board
N
5
PER QUOTE DRAWING No.
Wiring schematic
208-240Vac
50-60Hz
L
C
4
Diesel Engine Fire Pump Controller
24VDC Negative Ground
IS1
B
2
J105 / G-63
(P.2 / C8)
A
1
D
E
E
VMB1
To I/O Diesel
Board
UP
(P.2 / D4)
F
F
I/O
G
DI0
COM
DI1
COM
DI2
COM
DI3
COM
DI4
COM
DI5
J5
COM
DI6
COM
-
24V
COM
J4
DI7
J14
G
Selector Switch
H
OFF
H
A
H
SS1
30
32
AUTO
31
I
I
HAND
0
1
2
3
4
5
6
7
Copyright © 2020 Tornatech Inc. All right reserved. This drawing and the information contained or depicted herein are the sole property of Tornatech Inc. Copies are communicated to the recipient in strict confidence and may not be retransmitted, published, reproduced, copied or used in any manner, including as the basis for the manufacture or sale of any products, without the express prior written consent of Tornatech Inc.
8
P.2
0
A
1
2
3
4
5
6
7
8
PER QUOTE DRAWING No.
Diesel Engine Fire Pump Controller
24VDC Negative Ground
0
DD/MM/YY
DESCRIPTION
REV.
Model:GPD
Wiring schematic
NYC
Dpt of Building
Approved
As Built
DRAWING
07/07/20 NUMBER
Built to the latest edition of the NFPA 20 standard
A
A 1124683-S1
(P.1 / C7)
(P.1 / C5)
C
(P.1 / C7)
To Charger 2
(P.1 / F7)
(P.1 / C5)
+
PT1
To Charger 1
Sensing
Line
Connection
(P.1 / C3)
C
To Filter
AB1
-
Green / Yellow
SV1
To Charger 2
B
To Charger 1
B
CB3
CB4
J24
J14
J17
J18
J4
J44
J106
11
83
8
8
82
D
82
11
83
63
63
6
6
62
CF2
B2-
B2+
CF1
B1-
B1+
AI1
+
_
+
J15
AI2
_
AI3
+
_
AI4
+
_
AI5
J16
DOWN
VBAT
Vac
19 20 21 22
62
24IN
White
Black
_
Red
Brown
53 54
UP
+
J50
15 16 17 18
I/O
SV
AB
D
Blue
Black
Red
To VMB1
J105
J107
E
E
DB1
I/O Diesel Board
F
12
11
11
10
9
5
4
3
2
1
312
311
310
305
304
303
8
J104
J103
302
IN5
301
IN4
MP-
IN3
MP+
IN2
NC
C
NO
NC
C
NO
NC
C
NO
NC
C
NO
NC
C
NO
NC
C
NO
IN1
J35
6
J25
NC
C
NO
J42
TB6
NC
C
NO
J40
TB5
NC
C
NO
J39
TB4
NC
C
NO
J38
TB3
NC
C
NC
C
NO
J37
TB2
NO
J36
TB1
F
*J1
12
11
11
10
9
8
6
5
4
3
2
1
312
311
310
305
304
nP
res
su
re
Te
mp
Lo
era
w
Ra
tur
Lo
w
e
w
Wa
En
ter
gin
Flo
eT
En
w
erg
em
pe
ize
rat
to
ure
Sta
rt S
ole
no
id
En
gin
eR
un
Ov
ers
Lo
pe
w
ed
Hig
O
hE
il P
ng
res
ine
su
re
Te
mp
era
tur
e
Ba
tte
ry
1
Ba
tte
Sta
ry
2
rt C
on
tac
Sta
tor
rt C
1
on
tac
tor
2
Gr
ou
nd
En
erg
ize
Gr
ou
to
nd
Sto
pS
ole
no
id
tio
ter
Wa
Su
c
od
ule
lM
Hig
hR
Lo
w
D
PL
H
aw
ng
rni
Wa
ntr
o
Co
Fa
ult
303
302
301
n
ctio
Ma
ule
od
lM
tro
Ele
c
tro
nic
in
Inj
Ele
ctr
on
ic
Co
n
ec
tio
n
SS
Fu
el
EC
M
High Fuel Level
Fuel Tank Leak
Water Reservoir Low
Remote Auto Start
Low Fuel Level
lfu
n
.P
Alt
nk
Ta
el
Fu
m
Ro
o
Pu
mp
os
Le
ak
le
Tro
ub
ble
Tro
u
gin
e
nO
HO
En
Ru
n
gin
e
En
Ai
Co
ntr
H
FF
/H
Po AND
siti
on
G
olle
r
(Fa Trou
il S ble
afe
)
G
I
I
* Remove this jumper to use this feature
0
1
2
3
4
5
6
7
Copyright © 2020 Tornatech Inc. All right reserved. This drawing and the information contained or depicted herein are the sole property of Tornatech Inc. Copies are communicated to the recipient in strict confidence and may not be retransmitted, published, reproduced, copied or used in any manner, including as the basis for the manufacture or sale of any products, without the express prior written consent of Tornatech Inc.
8
P.3
0
2
3
4
6
NYC
Dpt of Building
Approved
0
As Built
Built to the latest edition of the NFPA 20 standard
Alarm Contacts
Terminals Wire Size:
24 - 12 AWG
0.5 Nm
Terminals Wire Size:
24 - 12 AWG
0.5 Nm
I/O Diesel Board
L
IN 1
IS1
Low Fuel Level
IN 2
N
*J1
Water Reservoir Low
IN 3
Fuel Tank Leak
IN 4
G
C
Engine Connections
IN 5
High Fuel Level
- All wiring between the controller and diesel engine shall be stranded (NFPA20)
Network Connections
- Wiring between controller and engine (terminals 301, 302, 303, 304, 305, 310,
311, 312, 2, 3, 4, 5) must be #14AWG as minimum.
J25
- Wiring between controller and engine (terminals 6, 8, 11 [rated at 30A]) must be
stranded and sized according to distance.
Normally Closed
Opens to alarm
Controller Trouble
(Fail Safe)
Louver Activation
Contact
3
4
5
F
6
8
Engine Run
Overspeed
Low Oil Pressure
High Engine Temperature
Battery 1
Battery 2
Start Contactor 1
9
10
G
11
11
12
H
303
J104
3
J104
4
J104
5
J104
6
J104
8
J104
HOA in OFF/HAND
Position
Start Contactor 2
Ground
Ground
Energize to Stop Solenoid
10
J104
11
J104
11
J104
12
J104
TB1
C
C
NO
C
NC
Normally Opened
Closes to alarm
NO
TB2
C
NC
Normally Closed
Opens to alarm
D
NO
C
NC
Normally Opened
Closes to alarm
NO
TB3
C
NC
E
Normally Opened
Closes to alarm
Normally Closed
Opens to alarm
Engine Trouble
Normally Closed
Opens to alarm
C
NC
Normally Opened
Closes to alarm
Normally Closed
Opens to alarm
Normally Closed
Opens to alarm
Normally Closed
Opens to alarm
F
NO
C
Normally Opened
Closes to alarm
NO
TB5
C
NC
Normally Closed
Opens to alarm
301
TB4
C
NC
Normally Opened
Closes to alarm
Fuel Tank Leak
NO
NC
Normally Opened
Closes to alarm
Pump Room Trouble
NO
G
NO
C
NC
Normally Opened
Closes to alarm
NO
TB6
C
NC
Fuel Injection Malfunction
302
Electronic Control Module Warning
303
304
305 PLD Low Suction Pressure
305
High Raw Water Temperature
310
311 Low Raw Water Flow
312
NO
NC
Normally Closed
Opens to Activate
Normally Closed
Opens to alarm
J104
304 Electronic Control Module Fault
310
I
J104
9
301 Electronic Control Module Selector Switch in Alternate Position
302
1
2
Normally Closed
Opens to alarm
J103
Controller Terminal Strip
2
C
Normally Opened
Closes to alarm
Located on Main Board
NO
NC
Normally Opened
Closes to activate
Normally Closed
Opens to alarm
I/O Diesel Board
Energize to Start Solenoid
Normally Opened
Closes to alarm
Normally Opened
Closes to alarm
Engine Run
Modbus TCP/IP
B
I/O Diesel Board
Terminals Wire Size:
Shielded Female Connector RJ45
- Wiring between controller and engine (terminals 12 [rated at 10A or 22A for 20
seconds] 1, 9, 10 [rated at 10A]) must be stranded #10AWG as minimum.
A
A 1124683-S1
Terminals Wire Size:
14 - 6 AWG
1.8-2 Nm
Remote Auto Start
1
DRAWING
07/07/20 NUMBER
Field Connections
208-240Vac
50-60Hz
E
DD/MM/YY
DESCRIPTION
REV.
Model:GPD
8
Power Supply
B
D
7
PER QUOTE DRAWING No.
Diesel Engine Fire Pump Controller
24VDC Negative Ground
Terminals diagram
5
Controller Terminal Strip
A
1
H
311
Low Engine Temperature
I
312
* Remove this jumper to use this feature
0
1
2
3
4
5
6
7
Copyright © 2020 Tornatech Inc. All right reserved. This drawing and the information contained or depicted herein are the sole property of Tornatech Inc. Copies are communicated to the recipient in strict confidence and may not be retransmitted, published, reproduced, copied or used in any manner, including as the basis for the manufacture or sale of any products, without the express prior written consent of Tornatech Inc.
8
P.4
0
A
1
2
3
4
6
7
8
PER QUOTE DRAWING No.
Diesel Engine Fire Pump Controller
24VDC Negative Ground
Dimensions
5
NYC
Dpt of Building
Approved
0
DD/MM/YY
DESCRIPTION
REV.
Model:GPD
As Built
DRAWING
07/07/20 NUMBER
Built to the latest edition of the NFPA 20 standard
A
A 1124683-S1
ENC1
15
26-
16 "
Ø3/8" [Ø10] X4
[684]
26-1/8" [663]
B
10" [254]
23-3/4" [602]
BC1
B
22-1/4" [564]
9" [229]
AB1
0 - OFF
0 - OFF
BC2
CB1
CB2
CB3
CB4
C
54
C
0 - OFF
F1
0 - OFF
29-7/8" [760]
D
D
E
82
8
11
12
6
G
G
83
63
11
84
62
10
9
64
8
2
Internal Layout
47-⅞" [1208]
Designation
8-12" [216]
F
6
G
5
CF2
4
B2-
B2+
G
B1-
CF1
B1+
HV+
1
312
311
305
310
304
302
303
301
MP-
12
11
14
12
11
14
12
11
14
12
11
14
12
11
14
12
11
14
SS1
MP+
22
21
24
22
21
24
22
21
24
22
21
24
22
21
24
22
21
24
DB1
21 22 23 24 25 26 27 28 29 30
PT1
SV1
IS1
3
Danger
E
Vext
G
Vac
_
_
_
AI1
+
_
+
AI2
_
AI3
+
AI4
+
AI5
+
N
G
28-7/8" [734]
SV
27-5/8" [702]
3-13" [84]
Description
AB1
Alarm Bell
BC1-BC2
Charger
CB1-CB2
Circuit Breaker 10A
CB3-CB4
DC Breaker 16A
DB1
I/O Diesel Board
ENC1
Enclosure
Sens. Line
Connec.
1/2 " F.NPT
F1
Filter
Drain
3/8 " F.NPT
IS1
Isolating Switch 16A
PT1
Pressure Sensor
SS1
Selector Switch 3 positions
SV1
Solenoid Valve
VMB1
ViZiTouch Main Board
G
F
G
13-1/2" [343]
6-16" [154]
1-1 4" [31.5]
H
H
3-13" [84]
- Use Watertight Conduit and Connector Only.
- Protect Equipment Against Drilling Chips.
- Ambient Temperature : Between 39°F (4°C) and 104°F (40°C)
- Shipping Weight, Wall Mounted: Approximate 98 Lbs - 45 Kg
I
- Enclosure TYPE 2 (NEMA 2)
- All Dimensions are in Inches [Millimeters].
- Paint: Textured Red RAL 3002
0
1
2
3
4
5
6
I
Projection
7
Copyright © 2020 Tornatech Inc. All right reserved. This drawing and the information contained or depicted herein are the sole property of Tornatech Inc. Copies are communicated to the recipient in strict confidence and may not be retransmitted, published, reproduced, copied or used in any manner, including as the basis for the manufacture or sale of any products, without the express prior written consent of Tornatech Inc.
8
MAIN COMPONENTS
9
7
6
5
4
3
8
QTY.
1
1
DIESEL FUEL TANK 800 GAL.
800 GAL
2
1
TANK FILL CAP
2" NPT
3
1
AUXILIAR VENT
2" NPT
4
1
EMERGENCY VENT
4" NPT
5
1
EMERGENCY VENT 2
4" NPT
6
1
AUXILIAR VENT 2
2" NPT
7
1
LOW LEVEL SWITCH
1 1/4" NPT
8
1
FUEL LEVEL INDICATOR 48"
2" NPT
9
1
MALE CONNECTOR (FUEL RETURN)
1/2" NPTRF
10
1
OUTER WALL DRAIN
1" NPT
11
1
INNER TANK DRAIN
1" NPT
12
1
LEAK DETECTION
1" NPT
13
1
LOCKABLE VALVE (FUEL SUPPLY)
3/4" NPT
2
10
[254]
10
[254]
ITEM
10
[254]
DESCRIPTION
SIZE
EMPTY WEIGHT VERIFY!!! Kg.
WET WEIGHT 3984.192 kg
10
[254]
1
6
[152]
54 11/16*
[1390]
6
[152]
SOFTENER PIPE
SOFTENER PIPE
48
[1219]
13
3 1/2
[89]
CUSTOMER DATA
CUSTOMER: PAN AMERICAN ENERGY
END USER: REFINERIA - CAMPANA
SITE: ARGENTINA
PROJECT: --GPS #: 1078449 - REV 2
CUSTOMER P.O: 4100126575
SERVICE: DIESEL FIRE PUMP
10
12
15
[381]
11
TAG NO.
PUMP NO.
---
34
[864]
6
[152]
ENGINE NO.
---
6
[152]
103
[2616]
RP JOB
153200083
PUMP
TYPE AND MODEL ZW 14X10X24 F
COOLING
DIMENSIONS AND TOLERANCES
PER ASME Y14.5M-1994
UNLESS OTHERWISE SPECIFIED
ALL DIMENSIONS ARE
1/2
[ 12.7]
GENERAL NOTES:
1.- DIMENSION UNITS ARE IN INCHES [MILLIMETERS]
2.- UL-142 TANK LISTED.
3.- ACCESSORIES WITH DASHED LINEA WILL BE SUPPLIED BY
OTHERS.
4.- DIMENSIONS IN (*) ARE SUBJECT TO CHANGE DUE TO
SUPPLIER.
APPROVAL DRAWING NOTES
1. PURCHASER'S COMMENTS AND/OR CORRECTIONS, WITHIN THE SCOPE OF CONTRACT, WILL BE MADE ON THE FIRST COMPLETED CERTIFIED DRAWING SUBMITTED BY RUHRPUMPEN INC. PUMP DIVISION AND RETURNED FOR CORRECTION.
2. CORRECTIONS, ALTERATIONS, ADDITIONS AND/OR MODIFICATIONS OUTSIDE SCOPE OF CONTRACT OR MADE AFTER FIRST
SUBMITTAL, WILL REQUIRE AN ENGINEERING SERVICE CHARGE AND MAY CHANGE PRICE.
3. ITEMS CONDITIONALLY APPROVED OR NEEDING DEFERRED APPROVAL BY PURCHASER, MUST BE SPECIFICALLY STATED.
DELIVERY MAY BE AFFECTED.
PROPRIETARY NOTE
A
REV
SENT FOR APPROVAL
DESCRIPTION
REVISION HISTORY
G.PINA
ENGINEER
07/31/2020
DATE
RUH RPUMPEN
DRAWING TITLE
800 GAL. DIESEL TANK (DOUBLE WALL)
DWN. BY
THIS MATERIAL IS THE PROPERTY OF RUHRPUMPEN INC. AND IS FURNISHED FOR THE PURPOSE INDICATED. ANY AND
ALL CONFIDENTIAL, PROPRIETARY, PATENT AND OTHER RIGHTS, IN THE SUBJECT MATTER BEING RETAINED INCLUDING ANY EXCLUSIVE RIGHTS OF USE AND/OR MANUFACTURE AND/OR SALE, POSSESSION OF THIS MATERIAL DOES NOT CONVEY ANY PERMISSION TO REPRODUCE THIS MATERIAL, IN WHOLE OR PART, OR MANUFACTURE THE SUBJECT MATTER SHOWN THEREIN, OR DATE
USE THE CONFIDENTIAL OR PROPRIETARY INFORMATION THEREON. SUCH PERMISSION TO BE GRANTED ONLY BY AN OFFICER
OR OTHER AUTHORIZED AGENT OF RUHRPUMPEN INC., ITS DIVISIONS OR SUBSIDIARIES.
G.PINA
7/31/2020
CHKD. BY
SCALE
DRAWING NO.
J.GONZALEZ NONE
DATE
7/31/2020
SHEET NO
1
8025910353
REV
A
SECTION 5
Series 34
Air Release Valves
• Stainless Steel T316 Trim Standard
• Stainless Steel Floats Guaranteed
• Easily Serviced Without Removal From Pipeline
• Working Pressures to 800 PSI
• Engineered For Drip Tight Seal At Low Pressures
Cla-Val Series 34 Air Release Valves are designed to vent entrained
air that collects at high points in a pipeline. This valve continuously
eliminates air from a system by releasing small quantities of air before
large air pockets can occur. In many installations, continuing accumulations of air in the pipeline (lacking air release valves); cause flow
capacity to slowly decrease; power consumption slowly increases; unnoticeable at first, until flow drops dramatically, even stopping due to
air blocks in the piping. Another problem resulting from excessive air
accumulation is un-explained pipeline rupture. These ruptures are
passed off as the result of ground settling or defective pipe, Where as
in reality its large air pockets that greatly increase pressure surges
(normally occurring) when flow stops and starts causing the rupture.
During normal pipeline operation, air accumulation at the high point will
displace the liquid within the air valve and lower the water level in relation to the float. As level of the liquid lowers, where the float is no longer
buoyant, the float drops and opens the valve orifice seat and permitting
accumulated air to be exhausted to atmosphere. After air is released,
the liquid level in the air valve rises and closes the valve orifice seat.
This cycle automatically repeats as air accumulates inside the air
release valve, thereby preventing the formation of air pockets
Installation
Specifications
Series 34 Air Release Valves are typically installed at highpoints in pipelines and at regular intervals, of approximate
1/2 mile, along uniform grade line pipe.
Sizes
1/2", 3/4", 1", 2", 3" NPT
Mount the unit in the vertical position on top of the pipeline
with an isolation valve installed below each valve in the
event servicing is required. A vault with adequate air venting
and drainage is recommended.
Pressure Ratings
150 psi
300 psi
800 psi
Note:
Temperature Range
Water to 180°F
Internal Parts:
Stainless Steel T316
Note: Specify when operating
pressure below 10 PSI
Seal:
Viton , Buna-N
Vacuum check valves can be supplied on the discharge of
all size air release valves to prevent air re-entering the system;
during negative pressure conditions
Purchase Specifications
(see note)
Materials
Body and Cover:
Cast Iron ASTMA-126, Class B
Float:
Stainless Steel T316
TM
®
The air release valve shall be of the float operated, simple
lever or compound lever design, and capable of
automatically releasing accumulated air from a fluid system
while the system is pressurized and operating.
The float shall be of all stainless steel construction and guaranteed to withstand the designed system surge pressure without failure. The body and the cover shall be cast iron and valve
internal parts shall be stainless steel and the Viton Buna-N® for
water tight shut-off. All T316 Stainless Steel shall be Austenitic.
An adjustable designed orifice button shall be used to seal
the valve discharge port with drip-tight shut-off. The orifice
diameter must be sized for use within a given operating
pressure range to insure maximum air venting capacity.
The air release valve shall be manufactured per
ANSI/AWWA C512-04 Series 34 from
Cla-Val in Newport Beach, CA, U.S.A.
TM
AIR RELEASE VALVE DATA
FOR WATER AND
Air Release Valve Sizing for Water and Wastewater Pipelines
1. Air release valve sizing requires determining the volume of air that must be released from pipeline high points during normal operation and the
diameter of the pipeline. Series 34 Air Release Valves are primarily used to continuously release pockets of air (as they develop) from high points.
Hence it is not critical to determine exact volume of air to be released.
2. If the volume of air to be released has been determined, then use the venting capacity chart to assist in sizing the air release valve. Use
maximum pipeline operating pressure (in psi) and flow (in SCFM) to determine orifice size. Select the largest inlet size for each valve to insure
adequate venting capacity.
INSTALLATION TIPS
1. The effectiveness of Series 34 Air Release Valve is dependent upon it being located at appropriate high points in a pipeline and
at uniform intervals of approximately 2500 feet on horizontal pipelines.
2. There are four variables that can cause an air pocket to form slightly downstream of the true high point in a piping system:
1. Severity of the slope adjacent to the high point or change of gradient
2. Velocity of the liquid
3. Texture of the inside surface of the pipe being used
4. Viscosity of the fluid
It is recommended where an air pocket can form slightly downstream of the high point, to install additional Series 34 Air Release
Valve at this point.
3. Cla-Val has available, upon request, a Slide Rule Air Valve Calculator. It will greatly reduce the amount of time to size
valves for pipeline service.
AIR RELEASE VALVE SIZING CHART FOR WATER PIPELINES
Pipeline
Diameter
(Inches)
Pumping
Capacity
(gpm)
2" - 3" - 4"
Diameter
200/800
gpm
6" - 8" - 10"
Diameter
800/2,2000
gpm
12" - 14"- 16" 2,000/5,000
gpm
Diameter
18" - 20" 5,000/15,000
gpm
Diameter
24" & Larger 15,000/50,000
gpm
Diameter
Model No.
34AR-116
34AR-116
34AR-116
34AR-332
34AR-332
34AR-332
34AR-018
34AR-018
34AR-316C
34AR-316C
34AR-38C
34AR-38C
PIPELINE OPERATING PRESSURE
1 to 175 psi
1 to 300 psi
Inlet Size
Orifice Size
Model No.
Inlet Size
1/2"
1/16"
3/4"
N/A
1"
1/2"
34AR-116.3
1/2"
3/32"
3/4"
34AR-116.3
3/4"
1"
34AR-116.3
1"
34AR-116.3
3/4"
3/4"
1/8"
1"
1"
34AR-116.3
1"
34AR-332.3C
1"
3/16"
2"
34AR-332.3C
2"
3/8"
2"
34AR-732.3C
2"
3"
34AR-732.3C
3"
3/8"
Orifice Size
1/16"
5/64"
3/32"
7/32"
7/32"
AIR RELEASE VALVE SIZING GUIDE FOR WASTEWATER PIPELINES
PIPELINE OPERATING PRESSURE
1 to 175 psi
1 to 300 psi
Model No.
Inlet Size
Orifice Size
Model No.
Inlet Size
34WW25-316
2"
34WW25-332
2"
3/16"
0 - 4,000
34WW35-316
3"
34WW35-332
3"
4" - 12"
gpm
34WW45-316
4"
34WW45-332
4"
34WW21-716
2"
34WW21-732
2"
7/16"
& Up 34WW31-716
3"
34WW31-732
3"
14" & Larger 4,100
gpm
34WW41-716
4"
34WW41-732
4"
Note: Use large as possible inlet size to allow best wastewater exchange to lesson clogged inlets.
Optional: Back Wash Kit recommended for maintenance.
Pipeline
Diameter
(Inches)
Pumping
Capacity
(gpm)
Orifice Size
3/16"
7/32"
When Ordering,
Please Specify:
1.
2.
3.
4.
Model Number
Inlet Size (NPT)
Inlet Pressure Rating
Orifice Size
Series 34
Series 34-WW
AND SIZING GUIDE
WASTEWATER
Simple Lever Type
(For Water)
N
o
A
i
r
A
i
r
O
u
t
i
n
For service up
to 300 psi
Air Release Valve for Water
Optional: Vacuum Check
Valve prevents air
re-entering system.
1/2” Model 50 VC
1” Model 1 VC
Model No.
Orifice Size
Inlet Size NPT Outlet Size NPT
34AR-116C
1/16"
1/2" - 3/4" -1"
3/8"
175 psi
34AR-332
3/32"
1/2" - 3/4" -1"
1/2"
175 psi
34AR-018
1/8"
3/4" -1"
1/2"
175 psi
34AR-316C
3/16"
1"
1/2"
175 psi
34AR-332.3C
3/32"
1"
1/2"
300 psi
34AR-316C
3/16"
2"
1/2"
175 psi
34AR-332-3C
3/32"
2"
1/2"
300 psi
34AR-038C
3/8"
2"
1"
175 psi
34AR-732.3C
7/32"
2"
1"
300 psi
34AR-038C
3/8"
2"
1"
175 psi
34AR-732.3C
7/32"
2"
1"
300 psi
34AR-732.2C
7/32"
2"
1"
500 psi
34AR-018C
1/8"
2"
1"
800 psi
34AR-1.6C
1"
6" Flanged
1"
150 psi
Air Release Valve for Wastewater
Compound Lever Type
(For Water)
34WW25-316
3/16"
2" - 3" -4"
1/2"
175 psi
34WW25-332
3/32"
2" - 3" -4"
1/2"
300 psi
34WW21-716
7/16"
2" - 3" -4"
1"
175 psi
34WW21-732
7/32"
2" - 3" -4"
1"
300 psi
ORIFICE SIZES WITH VENTING CAPACIT
FOR CLA-VAL AIR RELEASE VALVES
300
275
3/32
1/16
For Wastewater
250
6" Air Release Valve
5/64
Air Release Valve
(Pump Protector)
1/2
5/16
3/16
7/16
1/8
225
1/4
5/32
PRESSURE DROP
ACROSS ORIFICE (PSID)
For service up
to 800 psi
Max/ W.P.
3/8
200
175
150
125
100
75
50
25
0
E-34 (R-9/06)
1
10
AIR FLOW RATE (SCFM)
100
1000
PARTS LIST
Series 34
Air Release Valve – Simple Lever Type
4 3/4"
OUTLET
21
PIPE PLUG
OPTIONAL
4
2
6
17
3
7
34
13
12
5 1/4"
5
10
11
1
TEST PRESSURE
1.5 TIMES
WORKING PRESSURE
INLET
Detail No. Part Name
Material
Detail No.
1
Body
Cast Iron ASTM A126, Class B
10
2
Cover
Cast Iron ASTM A126, Class B
11
3
Lever Frame Stainless Steel T316, ASTM A276
12
4
Seat
Stainless Steel T316, ASTM A276
13
5
Float
Stainless Steel T316, ASTM A276
17
6
Gasket
Garlock #3000 (Non-Asbestos)
21
7
Cover Bolt
Alloy Steel SAE Grade 5
34
Valve
Size
1/2"
3/4"
1"
CLA-VAL
Model No.
175 psi
175 psi
Max. W.P.
Orifice
3450AR-116
3475AR-116
3410AR-116
1/16"
1/16"
1/16"
Part Name
Float Arm
Orifice Button
Pivot Pin
Pin Retainer
Float Retainer
Locator
Lock Washer
Material
Stainless Steel T316, ASTM A276
Viton
TM
Stainless
Stainless
Stainless
Stainless
Stainless
Inlet
Size
Outlet
Size
1/2"
3/4"
1"
1/2" NPT
1/2" NPT
1/2" NPT
Steel T316, ASTM A276
Steel PH 15-7 Mo
Steel T316, ASTM A276
Steel T316, ASTM A276
Steel T316, ASTM A276
Wt.
Lbs.
6
6
6
P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: [email protected] • Website cla-val.com
© Copyright
Cla-Val 2005 Printed in USA Specifications subject to change without notice.
PL-34AR116 (1/2” - 1”) (R-11/06)
PARTS LIST
Series 34
Air Release Valve – Simple Lever Type
1"
58
21
OUTLET
4
7
2
6
3
34
13
1
12
6"
10
5
11
17
TEST PRESSURE
1.5 TIMES
WORKING PRESSURE
INLET
Detail No. Part Name
Material
Detail No.
1
Body
Cast Iron ASTM A126, Class B
10
2
Cover
Cast Iron ASTM A126, Class B
11
3
Lever Frame Stainless Steel T316, ASTM A276
12
4
Seat
Stainless Steel T316, ASTM A276
13
5
Float
Stainless Steel T316, ASTM A276
17
6
Gasket
Garlock #3000 (Non-Asbestos)
21
7
Cover Bolt
Alloy Steel SAE Grade 5
34
Valve
Size
1/2"
3/4"
1"
CLA-VAL
Part Name
Float Arm
Orifice Button
Pivot Pin
Pin Retainer
Float Retainer
Locator
Lock Washer
Model No.
Model No.
175 psi
175 psi
300 psi
300 psi
Max. W.P.
Orifice
Max. W.P.
Orifice
3450AR-332 3/32" 3450AR-116.3
1/16"
3475AR-332 3/32" 3475AR-116.3
1/16"
3410AR-332 3/32" 3410AR-116.3
1/16"
Material
Stainless Steel T316, ASTM A276
Viton
TM
Stainless
Stainless
Stainless
Stainless
Stainless
Inlet
Size
1/2"
3/4"
1"
Steel T316, ASTM A276
Steel PH 15-7 Mo
Steel T316, ASTM A276
Steel T316, ASTM A276
Steel T316, ASTM A276
Outlet
Size
1/2" NPT
1/2" NPT
1/2" NPT
Wt.
Lbs
8
8
8
P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: [email protected] • Website cla-val.com
© Copyright
Cla-Val 2005 Printed in USA Specifications subject to change without notice.
PL-34AR (332/116) (R-11/06)
50B-4KG1 Globe
2050B-4KG1 Angle
MODEL
Fire Protection Pressure Relief Valve
E
S
OF
S
U N D E R W RIT
R
CANADA
BLLED BY
LA
ULC
LAB
O R AT O
RI
E
• U.L. Listed / U.L.C. Listed
• Factory Mutual Approved
• Fast Opening to Maintain Steady Line Pressure
• Accommodates Wide Range of Flow Rates
• Closes Gradually for Surge-Free Operation
• Adjustable Pressure Settings, Not Affected by
Pressure At Valve Discharge
The Cla-Val Model 50B-4KG1 Globe / 2050B-4KG1 Angle
Pressure Relief Valve is designed specifically to automatically relieve excess pressure in fire protection pumping systems. Pilot controlled, it maintains constant system pressure at the pump discharge within very close limits as
demands change. The 50B-4KG1 and 2050B-4KG1 can be
supplied with optional internal and external epoxy coating of
the main valve wetted surfaces.
U.L. Listed...............Sizes 3" thru 10"
F.M. Approved.........Sizes 3" thru 10"
U.L.C. Listed............Sizes 2” thru 10”
2050B-4KG1 (Angle)
Typical Application
KOModel 2050B-4KG1
Pressure Relief Valve
(Angle Pattern)
Operation Sequence
At pump start, Cla-Val Relief Valve modulates to relieve
excess pump capacity, maintaining positive system pressure at the pump discharge.
When fire demand slows or ceases, Cla-Val Model
50B-4KG1 opens, diverting entire pump output to discharge, allowing fire pump to be stopped without causing
surging in the lines.
Fire Pump
Check Valve
(Please note that if the Model 50B-4KG1 is to be used on
a continuous duty basis to maintain fire-system pressure,
suitable back pressure must be provided on the valve to
prevent cavitation damage. Consult the factory for details.)
"Fluid Control at It's Best"
To Fire
Protection System
Specifications
Dimensions
B
Sizes Globe: 2" - 10” flanged
Angle: 2" - 10" flanged
End Details 150 and 300 ANSI B16.42
Pressure Ratings class - 175 psi Max.
G
= U.L., F.M. sizes
class - 300 psi Max
Water, to 180°F Max.
Model 50B-4KG1 Globe
Materials Main Valve Body & Cover
Model 2050B-4KG1 Angle
Ductile Iron ASTM A-536
Naval Bronze ASTM B61
Other Material Available
Standard Main Valve Trim:
Bronze Seat, Teflon Coated
Stainless Steel Stem, Dura-Kleen Stem
Standard Pilot Control System:
Cast Bronze with
Stainless Steel trim
E
H
A
C
C
D
F
Adjustment Range Available in the following relief
pressure ranges:
20-200 psi (150 Class)
100-300 psi (300 Class)
We recommend providing adequate space around valve for maintenance work.
Valve Size
Optional Protective epoxy resin coating
of wetted surfaces of main
valve cast iron components
(UL listed HNFX EX2855)
The Fire Pump Pressure Relief Valve shall modulate to relieve excess
pressure in a fire protection system. It shall maintain constant pressure
in the system regardless of demand changes. It shall be pilot controlled
and back pressure shall not affect its set point. It shall be actuated by
line pressure through a pilot control system and open fast in order to
maintain steady system pressure as system demand decreases. It shall
close gradually to control surges and shall re-seat drip-tight within 5% of
its pressure setting. The main valve shall be of the hydraulically-operated, pilot-controlled, diaphragm-type, globe or angle valve. It shall have
a single, removable, teflon-coated seat, a grooved stem guided at both
ends, and a resilient disc with a rectangular cross section, being contained on 3 1/2 sides. No external packing glands shall be permitted and
the diaphragm shall not be used as a seating surface. The pilot control
shall be a direct-acting, adjustable, spring-loaded, diaphragm-type valve
designed for modulating service to permit flow when controlling pressure
exceeds spring setting. This valve shall be UL Listed and Factory Mutual
approved. It shall be the Model 50B-4KG1 (globe) or Model 2050B4KG1 (angle) Pressure Relief Valve as manufactured by Cla-Val Newport
Beach, California.
*Special Note:
The Model 50B-4KG1 Pressure Relief Valve is available with 300# ANSI
inlet flange and 150# ANSI outlet flange. This valve is used on higher
pressure systems where 300# flange connections are required, and
allows for adapting of a discharge cone (generally supplied with 150#
flange) to accommodate "atmospheric break" at relief valve discharge.
This relief valve, with 300# / 150# flanges is available on special order,
and is UNDERWRITERS LABORATORIES LISTED AND FACTORY
MUTUAL APPROVED.
Seawater Service Option
Globe: 2" - 10" flanged
Angle: 2" - 10" flanged
Consult factory for materials and flange ratings.
Sizes
2-1/2”
3”
4”
6”
8”
9.38
11.00
12.50
---
---
---
---
A 150 Flanged
9.38
11.00
12.00
15.00
20.00
25.38
29.75
300 Flaanged
10.00
11.62
13.25
15.62
21.00
26.38
31.12
12.88
15.31
20.56
25.88
30.44
(inches)
300 X 150
Purchase Specifications
Specifications
2”
Threaded Ends
B
3.31
4.00
4.56
5.75
7.88
10.00
11.81
C
12.00
12.25
12.50
13.00
14.31
16.31
18.00
D
1.50
1.69
2.66
3.19
4.31
5.31
9.25
Threaded Ends
4.75
5.50
6.25
---
---
---
---
E 150 Flanged
4.75
5.50
6.00
7.50
10.00
12.75
14.88
300 Flanged
15.56
5.00
5.88
6.38
7.88
10.50
13.25
Threaded Ends
3.25
4.00
4.50
---
---
---
---
F 150 Flanged
3.25
4.00
4.00
5.00
6.00
8.00
8.62
300 Flanged
3.50
4.31
4.38
5.31
6.50
8.50
9.31
6.00
6.69
7.75
7.88
8.50
9.75
13.25
250
G&H
Valve Size
50
65
80
100
150
200
Threaded Ends
238
279
318
---
---
---
---
A 150 Flanged
234
279
305
381
508
645
756
300 Flaanged
254
295
337
397
533
670
790
300 X 150
---
---
327
389
522
657
773
B
84
102
116
146
200
254
300
C
305
311
1318
330
363
414
457
D
38
43
65
81
109
135
235
Threaded Ends
121
140
159
---
---
---
---
E 150 Flanged
121
140
152
191
254
324
378
300 Flanged
395
((mm)
127
149
162
200
267
337
Threaded Ends
83
102
114
---
---
---
---
F 150 Flanged
83
102
102
127
152
203
219
89
109
111
135
165
216
236
152
170
197
200
216
248
337
300 Flanged
G&H
Valve Capacity
Valve Sizes in Inches:
2" 2 1/2" 3"
Recommended GPM 208 300
CLA-VAL
4687 Christie Drive
Beamsville, Ontario
Canada L0R 1B4
Phone: 905-563-4963
Fax:
905-563-4040
E-Mail: [email protected]
E-50B-4KG1/2050B-4KGLl (R-5/2012)
4"
6"
8"
10"
NFPA 20 Maximum
CLA-VAL EUROPE
Chemin des Mésanges 1
CH-1032 Romanel/
Lausanne, Switzerland
Phone: 41-21-643-15-55
Fax:
41-21-643-15-50
E-Mail: [email protected]
© Copyright CLA-VAL 2012 Printed in USA Specifications subject to change without notice.
500 1000 2500 5000 11000
Represented By:
PO Box 1325 Newport Beach CA 92659-0325 Phone: 949-722-4800
Fax: 949-548-5441 Web Site: cla-val.com E-mail: [email protected]
CLA-VAL CANADA
10”
CLA-VAL UK
Dainton House, Goods Station Road
GB - Tunbridge Wells
Kent TN1 2 DH England
Phone: 44-1892-514-400
Fax:
44-1892-543-423
E-Mail: [email protected]
INSTALLATION / OPERATION / MAINTENANCE
MODEL
50B-4KG1/2050B-4KG1
Pressure Relief Valve
The Cla-Val Model 50B4KG-1 Globe /2050B-4KG Angle Pressure
Relief Valve is designed specifically to automatically relieve
excess pressure in fire protection pumping systems. Pilot controlled, it maintains constant system pressure at the pump discharge within very close limits as demands change.
The Fire Pump Pressure Relief Valve shall modulate to relieve
excess pressure in a fire protection system. It shall maintain constant pressure in the system regardless of demand changes. It
shall be pilot controlled and back pressure shall not affect its set
point. It shall be actuated by line pressure through a pilot control
system and open fast in order to maintain steady system pressure
as system demand decreases. It shall close gradually to control
surges and shall re-seat drip-tight within 5% of its pressure setting.
INSTALLATION
1. Allow sufficient room around the valve assembly to make
adjustments and for servicing.
2. lt is recommended that gate or block valves be installed to
facilitate isolating valve for preventative maintenance. When used
as a surge control or pressure relief valve where valve outlet discharge is to atmosphere, then a gate or block valve is needed at
valve inlet. When used as a back pressure sustaining control
valve where valve outlet is connected to pressurized downstream
system, then gate or block valves are needed at valve inlet and
outlet.
NOTE: BEFORE THE VALVE IS INSTALLED, PIPE LINES
SHOULD BE FLUSHED OF ALL FOREIGN MATTER.
3. Place valve in line with flow through valve in direction indicated
on inlet plate or flow arrows. Check all fittings and hardware for
proper makeup and verify that no apparent damage is evident.
4. Cla-Val Valves operate with maximum efficiency when mounted
in horizontal piping with the cover UP; however, other positions are
acceptable. Due to size and weight of cover and internal components
on six inch and larger valves, installation with the cover up is
advisable. This makes periodic inspection of internal parts readily
accessible.
UL
®
MAINTENANCE
1. Cla-Val Valves and Controls require no lubrication or packing
and a minimum of maintenance. However, a periodic inspection
schedule should be established to determine how the fluid is
affecting the efficiency of the valve assembly. Minimum of once
per year.
2. Repair and maintenance procedures of the Hytrol Main Valve
and control components are included in a more detailed IOM
manual. It can be downloaded from our web site (www.cla-val.com)
or obtained by contacting a Cla-Val Regional Sales Office.
3. When ordering parts always refer to the catalog number
and stock number on the valve nameplate.
SYMPTOM
Main valve
won't open
Inlet pressure below setting of
pilot valve
Pilot valve stuck closed Mineral
deposit or foreign material between
disc retainer and power unit body
5. Caution must be taken in the installation of this valve to insure that
galvanic and/or electrolytic action does not take place. The proper use
of dielectric fittings and gaskets are required in all systems using dissimilar metals.
OPERATION AND START-UP
1. Prior to pressurizing the valve assembly make sure the necessary gauges to measure pressure in the system, are installed
as required by the system engineer.
CAUTION: During start-up and test a large volume of water
may be discharged downstream. Check that the downstream
venting is adequate to prevent damage to personnel and equipment. All pilot adjustments should be made slowly in small
increments. If the main valve closes too rapidly it may cause
surging in upstream piping.
2. Remove cap from CRL then loosen adjusting screw counterclockwise. This will allow the valve to open at low pressure relieving the full flow of the fire pump. Bleed all air from the valve at this
time by carefully loosening the cover plug and tube fittings at the
high points. Slowly turn the adjusting screw clockwise on the CRL
while watching the gauge between the valve and the pump until
you reach the desired set-point. Tighten the jam nut on the CRL
and replace the cap. DO NOT USE THE GAUGE PROVIDED ON
THE VALVE TO SET THE VALVE. IT IS ONLY THERE TO INDICATE PRESSURE IN THE COVER.
PROBABLE CAUSE
REMEDY
Reset pilot valve. If change
in setting is from tampering,
seal cap with wire and
lead seal
Disassemble control and clean
Pilot valve diaphragm ruptured or
Disassemble and replace
diaphragm nut loose. Water coming diaphragm Tighten nut
out of the vent hole in cover
Main valve stuck closed
Disassemble main valve,
Mineral buildup on stem
Stem damaged
parts and/or replace damaged
part. Check downstream
Inlet pressure above setting of
pilot valve
Reset pilot valve
clean
Main valve
won't close
Clogged needle valve or strainer
Disassemble and clean
Pilot valve stuck open. Mineral
deposit or foreign material under
disc retainer or under diaphragm
assembly
Disassemble and clean
Main valve stuck open. Mineral
buildup on stem. Foreign material
between seat and disc assembly
Disassemble and clean
Main valve diaphragm worn
Disassemble and replace
Valve leaks Pilot valve disc worn out
Disassemble and replace
Continuously Main valve disc worn or small
Disassemble and replace
pin hole in main valve diaphragm
Set point too close to inlet pressure Reset CRL Pilot
50B-4KG-1 SCHEMATIC
X140-1
Security Cap
Option
CRL
2.
Cap
2
Screw, Adjusting
Nut Hex (Locking)
4
3
Cover
Guide, Spring
Spring
5
Washer, Belleville
Guide, Spring
Nut, Stem, Upper
Washer, Diaphragm
(Upper)
Screw Fil. Hd.*
1/8 - 27 NPT
SENSING
CONNECTION
INLET
6
Diaphragm*
Washer, Diaphragm
(Lower)
OUTLET
*O-Ring, Stem
O-Ring, Stem*
Stem
1
BASIC COMPONENTS
1 100-06 Hytrol (Main Valve)
2 CRL Pressure Relief Control
3 X44A Strainer & Orifice Strainer
4 81-01 Check Valve
5 Pressure Gauge
6 X46A Flow Clean Strainer
1.
Nameplate
*Disc Retainer Assy.
OUTLET
INLET
1/2" or 3/4" NPT
(2 places)
Body
Nut, Stem, Lower
O-Ring, Seat*
HYTROL MAIN VALVE
Seat
PIPE PLUG
CRL (20 - 200 psi) configuration shown
HEX NUT
COVER
Body, Powerunit
O-Ring, Body*
8" and Larger
PIPE PLUG
CRL adjust range (psi)
Spring Color
psi change per turn
0 - 75
Red
8.5
20 - 200
Green
28
100 - 300
Yellow
18
Cover Bolt
6" and Smaller
COVER BEARING
SPRING
* approximate. Use gauge at valve inlet to set
STEM NUT
DIAPHRAGM WASHER
CRL
*DIAPHRAGM
2.
X44A
3.
DISC RETAINER
*SPACER WASHERS
*DISC
DISC GUIDE
STEM
Pressure Gauge
Seat Screw
5.
8" and Larger
SEAT
X46A
6.
SEAT O-RING
STUD
8" and Larger
BODY
PIPE PLUG
(Globe or Angle)
*Repair Parts
CLA-VAL
For a more detailed IOM Manual go to www.cla-val.com or contact a
Cla-Val Regional Sales Office.
P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: [email protected] • Website cla-val.com
©
Copyright Cla-Val 2013 Printed in USA Specifications subject to change without notice.
N-50B4KG1/2050B4KG1 (R-1/2013)
Mechanical
pressure measurement
Bourdon tube pressure gauge, copper alloy
Standard version
Models 111.10, 111.12
WIKA data sheet PM 01.01
for further approvals
see page 3
Applications
■■ For gaseous and liquid media that are not highly viscous
or crystallising and will not attack copper alloy parts
■■ Pneumatics
■■ Heating and air-conditioning technology
■■ Medical engineering
Special features
■■ Reliable and cost-effective
■■ Design per EN 837-1
■■ Nominal size 40, 50, 63, 80, 100 and 160
■■ Scale ranges up to 0 ... 400 bar
Fig. left: Model 111.12, back mount
Fig. right: Model 111.10, lower mount (radial)
Description
The model 111 pressure gauges are based on the proven
Bourdon tube measuring system. On pressurisation, the
deflection of the Bourdon tube, proportional to the incident
pressure, is transmitted to the movement via a link and
indicated.
The modular design enables a multitude of combinations
of case materials, process connections, nominal sizes and
scale ranges. Due to this high variance, the instrument
is suitable for use in a wide range of applications within
industry.
WIKA data sheet PM 01.01 ∙ 06/2017
Data sheets showing similar products:
Panel mounting series; models 111.16, 111.26; see data sheet PM 01.10
With VdS approval; model 111.12.040; see data sheet SP 01.23
For mounting in control panels, the pressure gauges can,
depending on the process connection, be fitted with a
surface mounting flange or with a triangular bezel and
mounting bracket.
The standard version of the model 111 is manufactured,
cost-optimised on modern production lines, in volumes of
several million instruments per year.
Page 1 of 5
Specifications
Options
Design
EN 837-1
■■ Other process connection
Nominal size in mm
40, 50, 63, 80, 100
160 only with model 111.10
■■ Model 111.10: Surface mounting flange
Accuracy class
2.5
Scale ranges
0 ... 0.6 to 0 ... 400 bar (NS 160: max. 40 bar)
or all other equivalent vacuum or combined pressure and
vacuum ranges
Pressure limitation
Steady:
3/4 x full scale value
Fluctuating: 2/3 x full scale value
Short time:
Full scale value
Permissible temperature
Ambient: -20 ... +60 °C
Medium: +60 °C maximum
Temperature effect
When the temperature of the measuring system deviates
from the reference temperature (+20 °C): max. ±0.4 %/10 K
of the span
Process connection
Copper alloy
For process connections and spanner widths see page 4
■■ Accuracy class 1.6
■■ Steel case, black
(not with NS 40 and 50)
■■ Model 111.12: Triangular bezel with mounting bracket
Special versions
For closed heating systems
NS 63, 80
with red mark pointer and adjustable green sector, scale
ranges 0 ... 4 bar, red mark at 2.5 or 3 bar
For refrigeration plants
NS 63, 80
with additional temperature scale in °C for refrigerants
For water-level indication (hydrometer) and heating
systems
NS 80, 100, 160
Scale ranges 0 ... 0.6 to 0 ... 25 bar, with second scale in
mWS and red mark pointer
For drinking water installations
Material suitability of the wetted parts in accordance
with the evaluation criteria for metallic substances of the
German federal environmental agency and the “4MS
Common Composition List”.
Pressure element
Copper alloy
C-type or helical type
Movement
Copper alloy
Dial
NS 40, 50, 63: Plastic, white, with pointer stop pin
NS 80, 100, 160: Aluminium, white, with pointer stop pin
Black lettering, red mark pointer with measuring ranges
0 ... 0.6 to 0 ... 60 bar
Pointer
Plastic, black
NS 160: Aluminium, black
Case
Plastic, black
Model 111.12, NS 100: Steel, black
Model 111.10, NS 160: Steel, black
Window
Plastic, crystal-clear, snap-fitted in case
Model 111.10, NS 160: Instrument glass
Page 2 of 5
WIKA data sheet PM 01.01 ∙ 06/2017
Approvals
Logo
Description
Country
EAC (option)
Pressure equipment directive
Eurasian Economic Community
GOST (option)
Metrology, measurement technology
Russia
KazInMetr (option)
Metrology, measurement technology
Kazakhstan
MTSCHS (option)
Permission for commissioning
Kazakhstan
BelGIM (option)
Metrology, measurement technology
Belarus
UkrSEPRO (option)
Metrology, measurement technology
Ukraine
-
CPA
Metrology, measurement technology
China
-
CRN
Safety (e.g. electr. safety, overpressure, ...)
Canada
-
EU declaration of conformity
Pressure equipment directive
European Union
Certificates (option)
■■ 2.2 test report per EN 10204 (e.g. state-of-the-art
manufacturing, material proof, indication accuracy)
■■ 3.1 inspection certificate per EN 10204 (e.g. indication
accuracy)
WIKA data sheet PM 01.01 ∙ 06/2017
Page 3 of 5
Dimensions in mm
Model 111.10, lower mount (radial)
NS
40
Dimensions in mm
a
9.5
b ±0.5
26
D
50
10
27.5
49
63
9.5
27.5
62
80
11.5
30
79
100
11.5
30.5
99
160
15.5
42
160
Weight in kg
G
h ±1
SW
14
0.08
G¼B
45
14
0.10
53.5
14
0.13
G½B
72
22
0.18
83.5
22
0.21
G½B
115.5
22
0.85
G⅛B
39
31132006_2.01
NS 80 and 100
31132006_1.01
NS 40, 50, 63 and 160
36
G¼B
G½B
Process connection per EN 837-1 / 7.3
Model 111.12, back mount
31132014.01
NS 40, 50, 63, 80 and 100
NS
Dimensions in mm
40
26
b1 ±0.5
b2 ±1
42
D
39
50
29.5
47.5
49
63
29
47
62
80
32
49
79
100
31
49
99
Weight in kg
G
SW
14
0.06
G¼B
14
0.07
G¼B
14
0.08
G¼B
14
0.11
G¼B
14
0.26
G⅛B
Process connection per EN 837-1 / 7.3
Page 4 of 5
WIKA data sheet PM 01.01 ∙ 06/2017
Ordering information
Model / Nominal size / Scale range / Process connection / Options
06/2017 EN
© 2005 WIKA Alexander Wiegand SE & Co. KG, all rights reserved.
The specifications given in this document represent the state of engineering at the time of publishing.
We reserve the right to make modifications to the specifications and materials.
WIKA data sheet PM 01.01 ∙ 06/2017
Page 5 of 5
WIKA Alexander Wiegand SE & Co. KG
Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Tel.
+49 9372 132-0
Fax
+49 9372 132-406
[email protected]
www.wika.de
FLO-­‐L10785-­‐SS FUEL SPILL SWITCH Fuel Spill Switch suitable for use with double wall diesel fuel tanks used in fire pump applications. Pre-­‐Assembled for Simple Installation! Just remove the existing fuel tank drain plug, thread in the fully assembled fuel spill switch assembly. Connect two wires to your alarm system and you’re done! The Flotronix Model FLO-­‐L10785-­‐SS fuel spill switch is ruggedly designed to detect fuel spill and leakage in the interstitial space of double wall diesel fuel tanks. It is constructed with corrosion resistant 304 Stainless Steel fittings and float switch assembly. The switch assembly is mounted in the 1” NPT annular space bottom drain connection found on most fuel tanks. When a leak occurs in the inner tank, the fuel drains into the installed fuel spill switch assembly. The float rises which closes the normally open contacts. The switch can be wired to either a fire pump controller or other alarm system to provide notification of fuel spill. SPECIFICATIONS Float Switch •
ANSI / U.L. 508 Listed •
All Stainless Steel Float Assembly •
Contact Rating: -­‐
PILOT DUTY ONLY -­‐
1A @ 200VDC/265VAC Max •
N.O. Normally Open closes when fuel is detected in assembly. Tee and Fittings •
304 Stainless Steel •
1” Tank Connection •
1 “ Test & Drain Plug Conduit Connections •
½” Threaded LB Powder Coated Aluminum C onduit Body Rated NEMA 4, UL22455 Shipping Weight: 3 lbs. Installation Notes: 1. Very Important! Install in the annular space drain, not the main tank drain. 2. Remove the annular space drain plug from the bottom of the fuel tank. 3. Remove the plastic CAPLUG from the 1” tank connection nipple provided on the fuel spill switch assembly. 4. Thread the assembly into the bottom of the tank and tighten using a pipe wrench on the tee fitting only. Do not use the electrical conduit body as a lever. Tighten with “test & drain” plug in front facing outward for easy inspection. 5. The electrical or alarm installer is provided with a ½” NPT conduit body for alarm connections. Alarm Testing: Removing the 1” test & drain plug from the side of the assembly can test the fuel spill switch. Using your finger gently push up on the float to active the alarm. After testing, reinstall the drain plug. Flotronix Corporation FLO-­‐L10785-­‐SS 2015 Subject to Change Without Notice www.flotronix.com Phone (317) 849-­‐7377 Fax (317) 849-­‐7337 Email [email protected] MODEL
WC-1
Waste Cone
• Available for Onshore and Offshore Applications
• Manufactured in Accordance with NFPA 20 Requirements
• Designed for use with UL/FM Approved Fire Pump
Pressure Relief Valves
Optional Materials for Seawater and Severe Service Applications:
•
•
•
•
•
Nickel Aluminum Bronze (NAB) - ASTM B148 Alloy C95800
Monel - QQ-N-288 Comp B - ASTM A494 Grade M30H
Cast Steel - ASTM A216 Grade WCB
316 Stainless Steel - ASTM A743 Grades CF3M and CFM8
Super Austenitic Stainless Steel - ASTM A351 Grade
CK3MCuN (SMO 254)
• Super Duplex Stainless Steel - ASTM A890 Grade 5A
(CE3MN)
Standards:
• Fusion Bonded Red Epoxy Coated
• Ductile Iron - ASTM A536-65
• (2) 2’’ 316 SS Sight Glasses per WC-1
• Single Body Casting (No Welding)
Flanges
• 150# Class (FF Standard)
• 300# Class (RF Standard)
• Raised Face and Flat Faced Options
Typical Application:
Fire Pump Relief
CLA-VAL
©
1701 Placentia Avenue • Costa Mesa CA 92627 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: [email protected] • Website cla-val.com
Copyright Cla-Val 2016 Printed in USA Specifications subject to change without notice.
WC-1
Technical Data & Dimensions
2
1
D
(B.C.D.)
F
(B.C.D.)
E
EQUALLY SPACED
A
AA
CC
INLET FLANGE
G
EQUALLY SPACED
C
OUTLET FLANGE
BB
B
6" X 8" SIZE SHOWN
Visit www.cla-val.com to learn
more about Cla-Val Fire
Protection Products
CLA-VAL
1701 Placentia Avenue • Costa Mesa CA 92627
800-942-6326 Fax: 949-548-5441 Web Site: cla-val.com E-mail: [email protected]
CLA-VAL CANADA
4687 Christie Drive
Beamsville, Ontario
Canada L0R 1B4
Phone: 905-563-4963
Fax:
905-563-4040
E-mail [email protected]
E-WC-1 (R-02-2016)
©COPYRIGHT
CLA-VAL EUROPE
Chemin des Mésanges 1
CH-1032 Romanel/
Lausanne, Switzerland
Phone: 41-21-643-15-55
Fax:
41-21-643-15-50
E-mail: [email protected]
CLA-VAL UK
Dainton House, Goods Station Road
Tunbridge Wells
Kent TN1 2 DH England
Phone: 44-1892-514-400
Fax:
44-1892-543-423
E-mail: [email protected]
CLA-VAL 2016 Printed in USA Specifications subject to change without notice.
CLA-VAL FRANCE
Porte du Grand Lyon 1
ZAC du Champ du Périer
France - 01700 Neyron
Phone: 33-4-72-25-92-93
Fax: 33-4-72-25-04-17
E-mail: [email protected]
CLA-VAL PACIFIC
45 Kennaway Road
Woolston, Christchurch, 8023
New Zealand
Phone: 64-39644860
www.cla-valpacific.com
E-mail: [email protected]
SECTION 6
PARTS
10
PROJECT No :
9
PRESSURE RELIEF VALVE
8
WASTE CONE, AIR RELEASE VALVE
7
PRESSURE GAUGE Y COMPOUND GAUGE
6
BATTERY RACK
5
DIESEL TANK
4
CONTROL PANEL
3
DIESEL ENGINE
2
PUMP
1
COMPLETE SYSTEM
PURCHASER NAME : PAN AMERICAN ENERGY
QUALITY ASSURANCE
MATERI
ALS
26-Jun-20
26-Jun-20
REVISION No. : 0
TAG No. : 001
CLIENT: PAN AMERICAN ENERGY
QUANTITY : 1
SERVICE : ERROR
MOTOR/ENGINE : C18H0-UFAD68, 687 HP, 1760 RPM, 230 VAC, 24 VDC
DOCS.
INSPECTIONS
DELIVERY DATE :
DESCRIPTION : DIESEL SYSTEM
1
2
3
4
5
6
7
8
9
10
Req.
TESTS AND REPORTS
ISSUE DATE :
PURCHASE ORDER No : 4100126575
PROJECT NAME : ---
INSPECTION POINTS
SPECIFICATION
INSPECTED BY:
ADITIONAL REQUIREMENTS / COMMENTS
No.
Req.
RUHRPUMPEN
PAN AMERICAN ENERGY
RUHRPUMPEN
Fabrication Program
X
X
X
REV
O.P. 7.2.0-01
REV
4100126575
JOSE CARLOS SEGURA
Procedures and Instructions
X
X
X
IC
RPQMS
REV
4100126575
MARIO LARA
Personnel Qualification
X
X
X
IC
O.P. 6.2.2-02
REV
4100126575
MARIO LARA
X
IC
O.P. 7.2.0-02
REV
4100126575
NELLY PEREZ
Measurement Instruments Certificates
X
X
PAN AMERICAN ENERGY
Bill of Materials
X
X
IC
W.I. 7.2.1-06
REV
4100126575
NELLY PEREZ
Warranty Letter
X
X
REV
O.P. 7.2.0-01
REV
4100126575
JOSE CARLOS SEGURA
Quality/Conformity Certificate
X
X
X
X
X
X
X
REV
O.P. 7.2.0-02
REV
4100126575
NELLY PEREZ
Installation and Operation Manual
X
X
X
X
X
X
X
X
REV
O.P. 7.2.0-02
REV
4100126575
NELLY PEREZ
Technical Databook / MRB
X
X
X
X
X
X
X
X
REV
O.P. 7.2.0-02
REV
4100126575
NELLY PEREZ
Mechanical Properties
X
X
REV
O.P. 7.2.0-01
REV
4100126575
BY VENDOR
Dimensional Inspection
X
X
X
IC
W.I. 7.2.1-08/W.I. 8.2.4-01
REV
4100126575
GERARDO ORTIZ
Paint Inspection
X
X
X
IT
W.I. 7.5.1-10 / W.I. 8.2.4-02
REV
4100126575
ELISEO DE LA CRUZ
X
IC
.I. 7.5.1-09/O.P. 7.5.1-03/W.I. 8.2.4-
REV
4100126575
ARTURO RIOS
X
IT
W.I. 8.2.4-01
REV
4100126575
MARIO LARA
X
IT
W.I. 8.2.4-04/W.I. 8.2.4-12/W.I. 8.2.4-2 REV
4100126575
ELISEO DE LA CRUZ
BALANCE PER ISO 1940/1 GRADE 2.5
X
IT
W.I. 8.2.4-03
NFPA-20 14.1.2.1, 14.1.2.2,
ANSI/UL 142 39.2
REV
4100126575
NORMA NAVARRETE
PUMP PRESSURE: 380 PSI @ 5 MINUTES
INCREASER PRESSURE 210 PSI @ 120 MINUTES
TANK PRESSURE: 5 PSI @ 30 MINUTES
X
IT
O.P. 4.4.0-02
REV
4100126575
RICARDO VAZQUEZ
X
REV
O.P. 7.2.0-02
REV
4100126575
BY VENDOR
X
REV
O.P. 7.2.0-02
REV
4100126575
ENGINEERING
X
REV
O.P. 7.2.0-02
REV
4100126575
ENGINEERING
X
REV
O.P. 7.2.0-02
REV
4100126575
ENGINEERING
X
REV
O.P. 7.2.0-02
REV
4100126575
ENGINEERING
Final Assembly / Packing Inspection
X
Assembly Inspection
X
Impeller Dynamic Balance
X
Hydrostatic Test
X
Performance Test
X
Driver performance
DRAWINGS
153200083
SALES ORDER No : 152800049
General Arrangement
X
X
Cross Sectional (Pump)
Lubrication List
X
X
X
Nameplates
X
PE HOLDING POINT
PA WARNING POINT
IT TOTAL INSPECTION
REV DOCUMENTARY REVIEW
IA RANDOM INSPECTION
IC CONTINUOUS INSPECTION
W WITNESSING
D DOCUMENTATION TO APPROVE
C CERTIFICATE REQUIRED
NELLY PEREZ
JOSE CARLOS SEGURA
DOCUMENTATION CTRL
PROJECT MANAGER
STD PERIOD: 12/18 MONTHS
1 COPY AND 1 ELECTRONIC
RP STANDARD GENERAL USAGE, RAL 3001
OPERATING CONDITIONS:
FLOW, RATED.....................................................: 4000 GPM
DIFFERENTIAL HEAD/ PRESSURE, RATED: 160 PSI
SPEED,
RATED...................................................: 1750 RPM
IMPELLER
DIAMETER, RATED........................: 19.25 IN
FLUID
TYPE..........................................................: CLEAN WATER
VAPOR PRESSURE, RATED.............................: 0.34 PSI.A
VISCOCITY, RATED.............................................: 1 cP
FLUID DENSITY, RATED/MAX………………...: 1.000/1.000 S.G.
PER UL, FM
PER UL, FM
CUSTOMER APPROVAL
DATE: ____/_____/_____
SECTION 7
Date
: Z2088
: R0002
Heat
BP Name
Element
C
Si
Mn
P
S
2017-02-20
RUHRPUMPEN INDUSTRIAL, S.A. DE C.V.
A 48 Cl. 35B / EN-GJL-250 (5.1301) EN 1561
:2017-02-22
BP Purchase order:
:
Project
Analysis
3.4200
1.7920
0.7700
0.0230
0.1000
Mechanical Properties
Tensile strength:
Yield point:
Elongation:
Area reduction:
Brinell Hardness:
36700.00Psi
0.00Psi *
0.0000% *
0.0000% *
0.0000
Microstructure
253.03MPa Nodularity: 0.00%
0.00MPa
Ferrite: 0 %
Perlite: 0 %
Part Information
Customer Part No. 1:
Fundemex Part No.: C11ZK03020
CASE LWH ZW 14X10X24F 115
Qty Pcs: 2
Heat treatment:
Visual test:MSS-SP55
Penetrant test:
Magnetic test:
Ultrasonic test:
Remarks
APPROVAL
QUALITY ASSURANCE
F-CA-25 REV.1
Date
: Z2112
: R0002
Heat
BP Name
Element
C
Si
Mn
P
S
2017-02-24
RUHRPUMPEN INDUSTRIAL, S.A. DE C.V.
A 48 Cl. 35B / EN-GJL-250 (5.1301) EN 1561
:2017-02-28
BP Purchase order:
:
Project
Analysis
3.4300
1.7980
0.7810
0.0220
0.0840
Mechanical Properties
Tensile strength:
Yield point:
Elongation:
Area reduction:
Brinell Hardness:
35600.00Psi
0.00Psi *
0.0000% *
0.0000% *
0.0000
Microstructure
245.45MPa Nodularity: 0.00%
0.00MPa
Ferrite: 0 %
Perlite: 0 %
Part Information
Customer Part No. 1:
Fundemex Part No.: C11ZK03020
CASE LWH ZW 14X10X24F 115
Qty Pcs: 1
Heat treatment:
Visual test:MSS-SP55
Penetrant test:
Magnetic test:
Ultrasonic test:
Remarks
APPROVAL
QUALITY ASSURANCE
F-CA-25 REV.1
Date
: Y6014
: R0001
Heat
BP Name
Element
C
Si
Mn
P
S
Ni
Cr
Mo
2016-06-03
RUHRPUMPEN, S.A. DE C.V.
A 351 Gr. CF8M - UNS J92900 / GX5CrNiMo19-11-2 (1.4408) EN 1
:2016-06-11
BP Purchase order:
:
Project
Analysis
0.0700
1.4440
0.5120
0.0320
0.0290
9.4020
18.7500
2.2040
Mechanical Properties
Tensile strength:
Yield point:
Elongation:
Area reduction:
Brinell Hardness:
Microstructure
80700.00Psi
44700.00Psi
49.8000%
0.0000% *
0.0000
556.40MPa Nodularity:
308.19MPa
Ferrite:
Perlite:
Part Information
0.00%
0 %
0 %
Customer Part No. 1:
Fundemex Part No.: C30ZI08100
IMP ZW 10X8X23F 139
Qty Pcs:
2
Heat treatment:ANNEALING SOLUTION 1050° C
Visual test:MSS-SP55
Penetrant test:
Magnetic test:
Ultrasonic test:
Remarks
APPROVAL
QUALITY ASSURANCE
F-CA-25 REV.1
Doc. No.
F450001
Hydrostatic Test Report
Part Number
14007699
Description
Standards and Documentation
Ruhrpumpen Global
CASE ZW 14X10X24
QTY
Part Number
Description
QTY
Part Number
Description
QTY
Part Number
Description
QTY
Part Number
Description
QTY
Project #
153200083
Customer
PAN AMERICAN ENERGY
174001079
Customer Order #
4100126575
JUL/28/2020
Date of Test
Required
380 PSI
5
Required Length
1
Input
17201874
Hydro Report Number
Hydrostatic Test Pressure
Prod. Order #
Input
Actual
380 PSI
Input
Minutes
5
Minutes
Chart Recording
input
Input
Surfactant
input
Input
Test Liquid
Water
Test Gage Number
Chloride Content
N/A
CT‐017
This Report is to certify that component(s) listed above
have been successfully hydrostatically tested
to the requirements above.
Performed By:
Witness By:
RAYMUNDO CARRIZALES
Rev.
00
Page
1 of 1
Date:
Date:
JUL/28/2020
DYNAMIC BALANCING TEST CERTIFICATE
BalanceMaster EasyBalance 2.2, Date: 2020-08-05, Time: 16:01
Maquinados Programados
Niquel 9213 Cd. Industrial Mitras
Garrcia, NL CP66000
Phone: (81)8158-5500
Fax:
ZW 14X10X24(F) 153200083 -15006538 OP CH(F=.375 D=19.375)1PZA
No Key Compensation
No Tooling Compensation
Balancing Quality Standard:
ISO G2.5
Rotor weight Left:
80.250 kg
CURRENT RESULT:
457 RPM
Correction Weight:
Unbalance:
Scale: 2.5 g
Service speed:
1750 RPM
Rotor weight Right:
80.250 kg
OK (0.10 x Tol)
Left
- 1.452 g at 227°
348.573 g-mm
OK (0.10 x Tol)
Right
- 1.407 g at 345°
337.593 g-mm
0
90
Scale: 2.5 g
270
180
Operator Signature ()
0
90
270
180
Verified By
Approved By
7.4.2.1